INTERNSHIP REPORT

PREPARED BY

Mr. K CHANNAVEER

01FE15BME065

At

Franke Faber India Pvt. Ltd.

1086/1/2, Sanaswadi, Tal - Shirur, Pune, Maharashtra 412208

This report is submitted to

School of Mechanical Engineering

K L E Technological University,
University Hubballi
 LIST OF CONTENTS

Chapter No Title Page No

1 INTRODUCTION 1-3

1.1 Introduction 1

1.2 Industrial training objective 2

1.3 The important of industrial training to student 3

2 COMPANY BACKGROUND AND ORGANIZATION 5-8

STRUCTURE

2.1 Organization chart 5

2.2 Company logo 8

3. WEEKLY JOBS SUMMARY 9-11

3.1 Weekly Jobs Summary 11

4 TECHNICAL CONTENTS 15-25

4.1 Details of machines, equipments & technology used etc. 15

5 FINDINGS AND RECOMMENDATIONS 25

6 CONCLUSIONS 30
 LIST OF TABLES

Table no Title Page no

3.1 Weekly Activities 14
4.1 Aerostation sparkle 18
4.2 Stilux 3D 19
4.3 Topaz 3D 21
4.4 Fusion 22
4.5 Supreme plus 23

LIST OF FIGURES

Figure no Title Page no

1 Faber worldwide 10
2 Map showing faber plant 12
3 Faber Entrance 12
4 Organization Chart 13
5 Aerostation sparkle 18
6 Stilux 3D 19
7 Topaz 3D 20
8 Fusion 22
9 Supreme plus 23
10 Laser cutting machine 24

School of Mechanical Engineering, K L E Technological University, Hubballi Page 3

 11 Bending 28
12 Bending process 31
13 Riveting process 335
14 Embossing Process 34
15 Welding Process 36
16 Hemming Process 38
17 Actual Fixture image 441
18 Glass pasting fixture 442
19 Supreme 3b Frame Fixture 43
20 AL pipe for 3 & 4 supreme cooktop 44
21 CAD model of fixture 45
22 CAD model of fixture 46
23 CAD model of the cooktop 46

School of Mechanical Engineering, K L E Technological University, Hubballi Page 4

 School of Mechanical Engineering

CERTIFICATE

Certified that the Internship work carried out by Mr. K CHANNAVEER, USN
01FE15BME065,, a bonafide student of KLE Technological University in partial fulfillment
for the award
rd of Bachelor of Engineering /Bachelor of Technology
chnology in Mechanical
Engineering of the K L E Technological University, Hubballi during the year 2018-19.
2018 It is
certified that all corrections/sugg
corrections/suggestions
estions indicated for Internal Assessment have been
incorporated in the Report deposited in the departmental library. The Internship report has
been approved as it satisfies the academic requirements in the said Degree.

Name : Name: Name:

Name
Signature: Signature: Signature:
(Internal Guide)) (Coordinator, SME) (Registrar)

External Viva
Name of the examiners Signature with date
1
2.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 5

 Franke Faber
F India Pvt. Ltd.
(1086/1/2,
1086/1/2, Sanaswadi, Tal - Shirur, Pune, Maharashtra 412208)

CERTIFICATE

Certified that the Internship work carried out by Mr. K CHANNAVEER USN
01FE15BME065, a bonafied
ed student of KLE Technological University, Hubballi in partial
fulfillment for the award
ward of Bachelor of Engineering in Mechanical Engineering of the K L E
Technological University, Hubballi during the year 2018-19.
2018 19. It is certified that, he has
completed the internship satisfactorily
satisfactorily.

Name: Ganesh Wable Name:

Signature: Signature:
(Industry Guide/Mentor) (Head
Head of organization)
organization

School of Mechanical Engineering, K L E Technological University, Hubballi Page 6

 Chapter 1

INTRODUCTION

Headquartered in Fabriano, Italy, Faber, the worldwide leader in kitchen hoods, was incepted
in 1955.
955. Since then, imagining, designing and manufacturing products that turn the kitchen
from just a space to an enjoyable experience for you. Faber has been the innovation driver in
kitchen technologies the world over and now has a turnover of €220 million. Add to it, the
talented global team responsible for inventing and patenting unique and user-friendly
user
technologies,
ies, it comes as no surprise that in certain parts of Europe, one hood out of two is a
Faber hood.

The company's dedication and determination to achieve its goals have allowed it to grow
from a local business to a European and global enterprise; thanks to acquisition of a number
of productive sites Faber is present in 3 continents, with 7 plants in 6 countries: Italy,
Sweden, France, Turkey, India and Argentina, plus a marketing office in the United States
and a representative office in Russia. Ongoing int
internationalisation
ernationalisation and openness to new
challenges brought Faber into the Franke Group in 2005, a major Swiss multinational leader
in Kitchen Systems, in which it is assigned the important role of Hoods Business Unit.

FRANKE FABER is India's leading kitchen appliances manufacturer with Italian origin and
has been a household name for the past 20 years. With its headquarter and plant in Pune, and
India being an important market, the plant will use futuristically designed state
state-of- the
artequipment and will be the export hub for Asia Pacific and Middle East regions.

Faber’s India vision and mission is to offer solutions in which aesthetics and practice of use
are always combined. Most importantly the mission is to be the ideal partner to our
customers while maintaining
intaining maximum attention to issues concerning Quality, Safety,and
Environment.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 7

1.2 Internship Training Objective

 Experience the discipline of working in a professional engineering organization.

 Apply engineering methods such as design and problem solving.

 Develop technical, interpersonal and communication skills

skills.

 Interact with other professional and non

non-professional groups.

 Develop understanding of the functioning and organization of a business.

1.3 The Importance of Industrial Training to Students

 Training helps to learn their jobs and attain desired levels of performance especially thus
contributing better utilization of employees, machines and materials.

 Training helps to reduce the cost of raw materials and products –reducing
reducing losses due to
waste, poor quality products and damage to machinery –which
which would result if an untrained
employee, were to learn on his own.

 Finally, training aids in the development of individual skills, better methods, new equipment
and new work relationship. Such
uch a process would also facilitate technological change by updating
the versatility of employees.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 8

 Chapter 2

Company background & Organization Structure

2.1 Organization Background

The company specializes inn the manufacture of chimneys, Gas cooki

cooking
ng appliances, Built
Built-in
microwave ovens and Dishwasher. In addition, the company also provides after sales
service/maintenance and repairs as well as the supply of spare parts to further complement
and support
port the selling of its products. At present, the ccompany has authorized dealers
worldwide.

Figure 1 Faber worldwide

HISTORICAL INNOVATIONS

Faber

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 Motor powered range hood – 1963

First to implement Glass Visor (vs. plastic) in traditional hood - 1966

First decorative canopy hood (The Nova) – 1986

First to implement glass visor (vs plastic) in traditional hoods – 1966

Faber becomes Franke- Faber – 2004

Use of robotic and automated technology in the production process

First with global production facilities in China, Turkey and Indi

India

Innovative products to meet sophisticated consumer market needs

Franke

1911 - Hermann Franke sets up a metal factory in Rorschach / Switzerland

1939 – Walter Franke takes over the business

1975 – Change of ownership: Willi Pieper takes over from Walter Franke

1988 – Introduction of the divisional structure

1989 – Michael Pieper becomes new owner and CEO

2002 – Strategic focus- Kitchen Systems(+ Air) / Washroom Systems (+ Water)

Water /
Foodservice Systems (+ Service) / Coffee Systems (+Servi
(+Service)
ce) / Beverage Systems (+Service)

2004 – Franke becomes the main shareholder in Faber group and renamed as Franke
Franke- Faber

2005 – Establishment of Franke Artemis Real Estate and Franke Artemis Industrial Participations

2010 – Establishment of Franke Artemis Group, Split of activities in Franke Kitchen Systems
Group / Franke Commercial Systems Group / Franke Artemis Real Estate Group / Franke Artemis
Asset Management Group

2011 – Franke celebrates its first hundred years of entrepreneurship

2012 – Establishmentt of Franke Faber Plant at Sanaswadi, Pune

School of Mechanical Engineering, K L E Technological University, Hubballi Page 10

 Figure 2 Map Showing Faber Plant

Figure 3 Faber Entrance

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 2.2 Organization Chart

Figure 4 Organization Chart

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 Chapter 3

WEEKLY JOBS SUMMARY

As a student of engineering in his or her industrial training as the requirement for award of
engineering, he or she must form a report involving the information and present the
knowledge that is acquired during the industrial Training.
Training. To make sure the marking of work
or the activity which has been made weekly in a table form
form.
Table 3.1 weekly activities

Date Activities
 Report to the HR and design head.
 Introduced by the officer to all of thestaff
15/1/2019  Introduction to all products of franke faber.
19/1/2019  Literature survey on recent trends in hood and hob
(week 1) industry.

21/1/2019  Understanding of different processes involved in the

26/1/2019 manufacturing of hood and hob.

(week 2)  Understanding the various components

nts of the hood and
hob.
 Assembly process of the hood and hob.
04/2/2019  Understanding the process of laser cutting.
09/2/2019  Learnt how to convert cad drawing to DFX for laser
(week 3) cutting.
 Nesting of drawing for laser cutting.

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 11/02/2019  Understanding bending process.
16/02/2019  Understanding bending diagram.
(week 4)  Understanding difficulties in bending for new design
developed.

18/02/2019  Understanding 5S responsibilities.

23/02/2019  Understanding the stores procedure.
(week 5)  Understanding spot welding process.
 Developing fixture for Supreme frames.
04/03/2019  Knowledge about drop test.
9/03/2019  Quality process.
(week 6)  Developing fixtures for glass pasting.
 Work on project.
11/03/2019  Work on sheet metal creo.
16/03/2019  Developing models in creo.
(week 7)  Work on project.

18/03/2019  Developing fixture for blower.

23/03/2019  Solving field problems in assembly line.
(week 8)  Learning SAP.
 Work on project.

25/03/2019  Pilot production.

30/03/2019  Identifying problems in pilot production.
(week 9)  Creating part code for new components in SAP.
 Work on project.
01/04/2019  Developing new cook top design.
06/04/2019  Creating spare codes in SAP
(week 10)  Basics in creating BOM
 Work on project.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 14

 Faber products

Aerostation Sparkle TC AB LTW 90

Figure 5 Aerostation sparkle

Specifications

Width 90

Finish Aligator Black

Control Premium Touch Control

Speed 3 + Intensive Speed

Filter 3 layer Baffle

Suction 1000 m3/hr

Lamp LED 2x1.5 watt

Control Premium Touch Control

Bio Colour LED for Speed Indication Speed 1 - Green; Speed 2 - Orange; Speed 3 -
Red

Purifier Specification

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 Nylon Filter Remove particles such as dust and dirt from the
air.

Carbon Filter Traps Odour, Gases and Neutralise them

HEPA 1.0 PM Filter High-Efficiency

Efficiency Particulate Air Filter which
removes

Dust, Smoke particles upto size of 1 Micron

STILUX 3D T2S2 TC LTW

Figure 6 Stilux 3D

Specifications

Width 60 cm

Finish Stainless steel + front glass

Suction 1095 m³/hr

Filter 3 layer baffle filter

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 Control Touch control

No. of Speeds 3+1

Noise level 62 dB (A)

Lamp LED 2x1.1 watt

Delay Yes

Intensive Speed Yes

TOPAZ 3D T2S2 BK TC LTW

Figure 7 Topaz 3D

Specifications

Width 60 cm

Finish Black conical with Front Glass

Suction 1095 m³/hr

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 Filter 3 layer baffle filter

Control Touch control

No. of Speeds 3+1

Noise level 62 dB (A)

Lamp LED 2x1.1 watt

Built-in Hobs

Fusion 724 CRX BR CI

Figure 8 Fusion

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 Specifications

Width 72 cm

Burners 4 burners

Number & type of burners 2 Triple Ring + 2 Double Ring burner

Pan support Cast Iron Finish

Granite cut dimension (LxWxH) mm 695 x 485 x 50 mm

Free standing Cooktops

Supreme Plus 4BB AI

Figure 9 Suoreme Plus

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 Specifications

Width 63.5 cm

Burners 4 brass burners

Frame Brush steel finish

Burners 1 small + 2 medium + 1 jumbo burner

Pan support Heat resistant euro coating square

Controls Feather touch knobs

Ignition Auto

Size (LxWxH) 635x500x55 mm

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TECHNICAL CONTENTS

1. Laser Cutting

Figure 10 Laser cutting machine

Laser cutting is a technology that uses a laser to cut materials, and is typical
typically
ly used for industrial
manufacturing applications, but is also starting to be used by schools, small businesses, and
hobbyists. Laser cutting works by directing the output of a high
high-power
power laser most commonly
through optics. The laser optics and CNC (computer
(computer numerical control) are used to direct the
material or the laser beam generated. A typical commercial laser for cutting materials involved a
motion control system to follow a CNC or G
G-code
code of the pattern to be cut onto the material. The
focused laser beam
m is directed at the material, which then either melts, burns, vaporizes away, or iis
blown away by a jet of gas, leaving an edge with a high-quality
high quality surface finish. Industrial laser
cutters are used to cut flat-sheet
sheet material as well as structural and piping
piping materials.

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1. Process

Industrial laser cutting of steel with cutting instructions programmed through the CNC
interface Generation of the laser beam involves stimulating a lasing material by electrical
discharges or lamps within a closed container. As the lasing material is stimulated, the beam
is reflected internally by means of a partial mirror, until it achieves sufficient energy to
escape as a stream of monochromatic coherent light. Mirrors or fiber optics are typically
used to direct the coherent light
ight to a lens, which focuses the light at the work zone. The
narrowest part of the focused beam is generally less than 0.0125 inches (0.32 mm). in
diameter. Depending upon material thickness, kerf widths as small as 0.004 inches (0.10
mm) are possible.[5] In order to be able to start cutting from somewhere other than the edge,
a pierce is done before every cut. Piercing usually involves a high
high-power
power pulsed laser beam
which slowly makes a hole in the material, taking around 55–15 seconds for 0.5-inch
inch-thick
(13
13 mm) stainless steel, for example. The parallel rays of coherent light from the laser source
often fall in the range between 0.06
0.06–0.08 inches (1.5–2.0
2.0 mm) in diameter. This beam is
normally focused and intensified by a lens or a mirror to a very small sp
spot
ot of about 0.001
inches (0.025 mm) to create a very intense laser beam. In order to achieve the smoothest
possible finish during contour cutting, the direction of beam polarization must be rotated as it
goes around the periphery of a contoured workpiece. For sheet metal cutting, the focal length
is usually 1.5–3 inches (38–76
76 mm).

Advantages of laser cutting over mechanical cutting include easier workholding and reduced
contamination of workpiece (since there is no cutting edge which can become contaminated
contaminat
by the material or contaminate the material). Precision may be better, since the laser beam
does not wear during the process. There is also a reduced chance of warping the material that
is being cut, as laser systems have a small heat-affected
heat zone. Somee materials are also very
difficult or impossible to cut by more traditional means.

Laser cutting for metals has the advantages over plasma cutting of being more precise and
using less energy when cutting sheet metal; however, most industrial lasers cannot
canno cut
through the greater metal thickness that plasma can. Newer laser machines operating at
higher power (6000 watts, as contrasted with early laser cutting machines' 1500 watt ratings)
are approaching plasma machines in their ability to cut through thick materials, but the

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 capital cost of such machines is much higher than that of plasma cutting machines capable of
cutting thick materials like steel plate.

2. Types

There are three main types of lasers used in laser cutting. The CO2 laser is suited for cutting,
c
boring, and engraving. The neodymium (Nd) and neodymium yttrium
yttrium-aluminium
aluminium-garnet
(Nd:YAG) lasers are identical in style and differ only in application. Nd is used for boring
and where high energy but low repetition are required. The Nd:YAG laser is used where very
high power is needed and for boring and engraving. Both CO 2 and Nd/Nd:YAG lasers can
be used for welding.

CO 2 lasers are commonly "pumped" by passing a current through the gas mix (DC-excited)
(DC
or using radio frequency energy (RF
(RF-excited).
). The RF method is newer and has become
more popular. Since DC designs require electrodes inside the cavity, they can encounter
electrode erosion and plating of electrode material on glassware and optics. Since RF
resonators have external electrodes they are not prone to those problems. CO2 lasers are used
for industrial cutting of many materials including titanium, stainless steel, mild steel,
aluminium, plastic, wood, engineered wood, wax, fabrics, and paper. YAG lasers are
primarily used for cutting and scribing metals and ceramics.

In addition to the power source, the type of gas flow can affect performance as well.
Common variants of CO2 lasers include fast axial flow, slow axial flow, transverse flow, and
slab. In a fast axial flow resonator, the mix
mixture
ture of carbon dioxide, helium and nitrogen is
circulated at high velocity by a turbine or blower. Transverse flow lasers circulate the gas
mix at a lower velocity, requiring a simpler blower. Slab or diffusion cooled resonators have
a static gas field thatt requires no pressurization or glassware, leading to savings on
replacement turbines and glassware.

The laser generator and external optics (including the focus lens) require cooling. Depending on
system size and configuration, waste heat may be transferred
transferred by a coolant or directly to air. Water
is a commonly used coolant, usually circulated through a chiller or heat transfer system.

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A laser microjet is a water-jet
jet guided laser in which a pulsed laser beam is coupled into a low
low-
pressure water jet. This iss used to perform laser cutting functions while using the water jet to guide
the laser beam, much like an optical fiber, through total internal reflection. The advantages of this
are that the water also removes debris and cools the material. Additional adv
advantages
antages over
traditional "dry" laser cutting are high dicing speeds, parallel kerf, and omnidirectional cutting.

Fiber lasers are a type of solid state laser that is rapidly growing within the metal cutting industry.
Unlike CO 2, Fiber technology utilizes a solid gain medium, as opposed to a gas or liquid. The
“seed laser” produces the laser beam and is then amplified within a glass fiber. With a wavelength
of only 1.064 micrometers fiber lasers produce an extremely small spot size (up to 100 times
smaller compared to the CO 2) making it ideal for cutting reflective metal material. This is one of
the main advantages of Fiber compared to CO 2.

Methods
There are many different methods in cutting using lasers, with different types used to cut different
material.
al. Some of the methods are vaporization, melt and blow, melt blow and burn, thermal stress
cracking, scribing, cold cutting and burning stabilized laser cutting.

Vaporization cutting
In vaporization cutting the focused beam heats the surface of the mater
material
ial to boiling point and
generates a keyhole. The keyhole leads to a sudden increase in absorptive quickly deepening the
hole. As the hole deepens and the material boils, vapor generated erodes the molten walls blowing
eject out and further enlarging the hole.
ole. Non melting material such as wood, carbon and thermoset
plastics are usually cut by this method.

Melt and blow

Melt and blow or fusion cutting uses high
high-pressure
pressure gas to blow molten material from the cutting
area, greatly decreasing the power requirem
requirement.
ent. First the material is heated to melting point then a
gas jet blows the molten material out of the kerf avoiding the need to raise the temperature of the
material any further. Materials cut with this process are usually metals.

Thermal stress cracking

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Brittle materials are particularly sensitive to thermal fracture, a feature exploited in thermal stress
cracking. A beam is focused on the surface causing localized heating and thermal expansion. This
results in a crack that can then be guided by moving the beam. The crack can be moved in order of
m/s. It is usually used in cutting of glass.

Reactive cutting

Also called "burning stabilized laser gas cutting", "flame cutting". Reactive cutting is like oxygen
torch cutting but with a laser beam as the ignition
ignition source. Mostly used for cutting carbon steel in
thicknesses over 1 mm. This process can be used to cut very thick steel plates with relatively little
laser power.

2. Bending

Figure 11 Bending

Bending is a manufacturing proc

process that produces a V-shape, U-shape,
shape, or channel shape
along a straight axis in ductile materials, most commonly sheet metal.Commonly used

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 equipment include box and pan brakes, brake presses, and other specialized machine presses.
Typical products that are made like this are boxes such as electrical enclosures and
rectangular ductwork.
Bending process

Figure 12 Bending Process

In press brake forming, a work piece is positioned over the die block and the die block presses the
sheet
heet to form a shape.[1] Usually bending has to overcome both tensile stresses and compressive
stresses. When bending is done, the residual stresses cause the material to spring back towards its
original position, so the sheet must be over
over-bent to achieve the proper bend angle. The amount of
spring back is dependent on the material, and the type of forming. When sheet metal is bent, it
stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as
measured from the outside edges
dges of the bend. The bend radius refers to the inside radius. The
formed bend radius is dependent upon the dies used, the material properties, and the material
thickness.

The U-punch forms a U-shape

shape with a single punch.

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Types

A schematic of coining with

ith a back gauge There are three basic types of bending on a press brake
each is defined by the relationship of the end tool position to the thickness of the material. These
three are Air Bending, Bottoming and Coining. The configuration of the tools for these
t three types
of bending are nearly identical. A die with a long rail form tool with a radiused tip that locates the
inside profile of the bend is called a punch. Punches are usually attached to the ram of the machine
by clamps and move to produce the bending
bending force. A die with a long rail form tool that has
concave or V shaped lengthwise channel that locate the outside profile of the form is called a die.
Dies are usually stationary and located under the material on the bed of the machine. Note that
some locations do not differentiate between the two different kinds of dies (punches and dies). The
other types of bending listed use specially designed tools or machines to perform the work.

Air bending
This bending method forms material by pressing a punch (also called the upper or top die) into the
material, forcing it into a bottom V
V-die,
die, which is mounted on the press. The punch forms the bend
so that the distance between the punch and the side wall of the V is greater than the material
thickness (T).

Either a V-shaped
shaped or square opening may be used in the bottom die (dies are frequently referred to
as tools or tooling). Because it requires less bend force, air bending tends to use smaller tools than
other methods.Some of the newer bottom tools are adjusta
adjustable,
ble, so, by using a single set of top and
bottom tools and varying press-stroke
stroke depth, different profiles and products can be produced.
Different materials and thicknesses can be bent in varying bend angles, adding the advantage of
flexibility to air bending.
ng. There are also fewer tool change
changes,
s, thus, higher productivity.

A disadvantage of air bending is that, because the sheet does not stay in full contact with the dies,
it is not as precise as some other methods, and stroke depth must be kept very accurate.
accurate Variations
in the thickness of the material and wear on the tools can result in defects in parts produced..
produced. Thus,
the use of adequatee process models is important
important.

Air bending's angle accuracy is approximately ±0.5 deg. Angle accuracy is ensured by

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 applying
ing a value to the width of the V opening, ranging from 6 T (six times material
thickness) for sheets to 3 mm thick to 12 T for sheets more than 10 mm thick. Springback
depends on material properties, influenc
influencing the resulting bend angle.

Depending on material
erial properties, the sheet may be overbent to compensate for springback.
Air bending does not require the bottom tool to have the same radius as the punch. Bend
radius is determined by material elast
elasticity rather than tool shape.

The flexibility and relatively

ively low tonnage required by air bending are helping to make it a
popular choice. Quality problems associated with this method are countered by angle
angle-
measuring systems, clamps and crowning systems adjustable along the x and y axes,
ax and
wear-resistant tools.

The K-factor
factor approximations given below are more likely to be accurate for air bending than
the other types of bending due to the lower forces involved in the forming process.

Bottoming
In bottoming, the sheet is forced against the V opening in the bo
bottom
ttom tool. U
U-shaped
openings cannot be used. Space is left between the sheet and the bottom of the V opening.
The optimum width of the V opening is 6 T (T stands for material thickness) for sheets about
3 mm thick, up to about 12 T for 12 mm thick sheets. The bending radius must be at least 0.8
T to 2 T for sheet steel. Larger bend radius require about the same force as larger radii in air
bending, however, smaller radii require greater force
force—up to five times as much—
—than air
bending. Advantages of bottoming
bottoming include greater accuracy and less springback. A
disadvantage is that a different tool set is needed for each bend angle, sheet thickness, and
material. In general, air bendingg is the preferred technique.

Coining
In coining, the top tool forces the material
material into the bottom die with 5 to 30 times the force of
air bending, causing permanent deformation through the sheet. There is little, if any, spring
back. Coining can produce an inside radius as low as 0.4 T, with a 5 T width of the V
opening. While coining
ng can attain high precision, higher costs mean that it is not often used.

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 Three-point bending
Three-point
point bending is a newer process that uses a die with an adjustable
adjustable-height
height bottom tool,
moved by a servo motor. The height can be set within 0.01 mm. Adju
Adjustments
stments between the
ram and the upper tool are made using a hydraulic cushion, which accommodates deviations
in sheet thickness. Three-point
point bending can achieve bend angles with 0.25 deg. precision.
While three-point
point bending permits high flexibility and precision,
precision, it also entails high costs and
there are fewer tools readily available. It is being used mostly in high-value
value niche markets.

Folding
In folding, clamping beams hold the longer side of the sheet. The beam rises and folds the
sheet around a bend profile.
ofile. The bend beam can move the sheet up or down, permitting the
fabricating of parts with positive and negative bend angles. The resulting bend angle is
influenced by the folding angle of the beam, tool geometry, and material properties. Large
sheets can
n be handled in this process, making the operation easily automated. There is little
risk of surface damage to the sheet.

Wiping
In wiping, the longest end of the sheet is clamped, then the tool moves up and down, bending the
sheet around the bend profile.
le. Though faster than folding, wiping has a higher risk of producing
scratches or otherwise damaging the sheet, because the tool is moving over the sheet surface. The
risk increases if sharp
rp angles are being produced.

This method will typically bottom or coin the material to set the edge to help overcome
springback. In this bending method, the radius of the bottom die determines the final bending
radius.

Rotary bending
Rotary bending is similar to wiping but the top die is made of a freely rotating cylin
cylinder with the
final formed shape cut into it and a matching bottom die. On contact with the sheet, the roll
contacts on two points and it rotates as the forming process bends the sheet. This bending method

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is typically considered a "non-marking"
marking" forming process
pro suitable to pre-painted
painted or easily marred
surfaces. This bending process can produce angles greater than 90° in a single hit on standard press
brakes process.

Elastomer bending
In this method, the bottom V-die
die is replaced by a flat pad of urethane or rubber. As the punch
forms the part, the urethane deflects and allows the material to form around the punch. This
bending method has a number of advantages. The urethane will wrap the material around the
punch and the end bend radius will be very close to the actual radius on the punch. It provides a
non-marring
marring bend and is suitable for pre-painted
pre painted or sensitive materials. Using a special punch
called a radius ruler with relieved areas on the urethane U
U-bends
bends greater than 180° can be achieved
in one hit, something
mething that is not possible with conventional press tooling. Urethane tooling should
be considered a consumable item and while they are not cheap, they are a fraction of the cost of
dedicated steel. It also has some drawbacks, this method requires tonnage similar to bottoming and
coining and does not do well on flanges that are irregular in shape, that is where the edge of the
bent flange is not parallel to the bend and is short enough to engage the urethane pad.

Joggling

A joggle bend in sheet metal and a joggling toolJoggling,

tool also known as joggle bending, is an
offset bending process in which the two opposite bends are each less than 90° (see following
section for how bend angle is measured), and are separated by a neutral web so that the offset (in
thee usual case where the opposite bends are equal in angle) is less than 5 workpiece thicknesses.
Often the offset will be one workpiece thickness, in order to allow a lap joint which is smooth on
the 'show-face'.

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 3. Riveting

Figure 13 Riveting Process

A rivet is a permanent mechanical fastener. Before being installed, a rivet consists of a

smooth cylindrical shaft with a head on one end. The end opposite to the head is called the
tail. On installation, the rivet is placed in a punched or drilled hole, and the tail is upset, or
bucked (i.e., deformed), so that it expands to about 1.5 times the original shaft diameter,
holding the rivet in place. In other words, pounding creates a new "head" on the other end by
smashing the "tail"
il" material flatter, resulting in a rivet that is roughly a dumbbell shape. To
distinguish between the two ends of the rivet, the original head is called the factory head and
the deformed end is called the shop head or buck-tail.
buck

Because there is effectively

vely a head on each end of an installed rivet, it can support tension
loads. However, it is much more capable of supporting shear loads (loads perpendicular to
the axis of the shaft).

Fastenings used in traditional wooden boat building, such as copper nai

nails
ls and clinch bolts,
work on the same principle as the rivet but were in use long before the term rivet was
introduced and, where they are remembered, are usually classified among nails and bolts
respectively

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 Types
There are a number of types of rivets, ddesigned
esigned to meet different cost, accessibility, and
strength requirements:
Solid/round head rivets

A typical technical drawing of a universal head solid rivet are one of the oldest and most
reliable types of fasteners, having been found in archaeological findings
findings dating back to the
Bronze Age. Solid rivets consist simply of a shaft and head that are deformed with a hammer
or rivet gun. A rivet compression or crimping tool can also deform this type of rivet. This
tool is mainly used on rivets close to the ed
edge
ge of the fastened material, since the tool is
limited by the depth of its frame. A rivet compression tool does not require two people, and
is generally the most foolproof way to install solid rivets.

Riveting team working on the cockpit shell of a C

C-47 transport at the plant of North American
Aviation. The woman on the left operates an air hammer, while the man on the right holds a
bucking bar.
Solid rivets are used in applications where reliability and safety count. A typical application for
solid rivets
ts can be found within the structural parts of aircraft. Hundreds of thousands of solid
rivets are used to assemble the frame of a modern aircraft. Such rivets come with rounded
(universal) or 100° countersunk heads. Typical materials for aircraft rivets aare
re aluminium alloys
(2017, 2024, 2117, 7050, 5056, 55000, V
V-65), titanium, and nickel-based
based alloys (e.g., Monel).
Some aluminum alloy rivets are too hard to buck and must be softened by solution treating
(precipitation hardening) prior to being bucked. "Ic
"Icee box" aluminum alloy rivets harden with age,
and must likewise be annealed and then kept at sub
sub-freezing
freezing temperatures (hence the name "ice
box") to slow the age-hardening
hardening process. Steel rivets can be found in static structures such as
bridges, cranes, and building frames.

The setting of these fasteners requires access to both sides of a structure. Solid rivets are driven
using a hydraulically, pneumatically, or electromagnetically actuated squeezing tool or even a
handheld hammer. Applications where only one side is accessible require "blind" rivets.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 32

Solid rivets are also used by some artisans in the construction of modern reproduction of medieval
armour, jewellery and metal couture.

High-strength
strength structural steel rivets

Structural steel rivets like thiss one were used in the construction of the Golden Gate Bridge in the
1930s.

Women rivet heaters, with their tongs and catching buckets, Puget Sound Navy Yard, May 1919
Until relatively recently, structural steel connections were either welded or riveted. High-strength
bolts have largely replaced structural steel rivets. Indeed, the latest steel construction specifications
published by AISC (the 14th Edition) no longer covers their installation. The reason for the change
is primarily due to the expense of sskilled
killed workers required to install high strength structural steel
rivets. Whereas two relatively unskilled workers can install and tighten high strength bolts, it takes
a minimum of four highly skilled riveters to install rivets.[citation needed]

At a central
tral location near the areas being riveted, a furnace was set up. Rivets were placed in the
furnace and heated to glowing hot (often to white hot) so that they were more plastic and easily
deformed. The rivet warmer or "cook" used tongs to remove individua
individuall rivets and throw them to a
catcher stationed near the joints to be riveted. The catcher (usually) caught the rivet in a leather or
wooden bucket with an ash-lined
lined bottom. He placed the rivet into the hole to be riveted, then
quickly turned to catch the next
ext rivet. The "holder up or holder on" would hold a heavy rivet set or
dolly or another (larger) pneumatic jack against the round head of the rivet, while the riveter
(sometimes two riveters) applied a hammer or pneumatic rivet hammer to the unformed head
head,
making it mushroom tightly against the joint in its final domed shape. Alternatively the buck is
hammered more or less flush with the structure in a counter sunk hole.[1] Before the use of
pneumatic hammers, e.g. in the construction of RMS Titanic, the m
man
an who hammered the rivet was
known as the "basher". Upon cooling, the rivet contracted and exerted further force, tightening the
joint.

The last commonly used high strength structural steel rivets were designated ASTM A502

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 Grade 1 rivets.[2]

Such riveted
ted structures may be insufficient to resist seismic loading from earthquakes if the
structure was not engineered for such forces, a common problem of older steel bridges. This
is because a hot rivet cannot be properly heat treated to add strength and hard
hardness.
ness. In the
seismic retrofit of such structures it is common practice to remove critical rivets with an
oxygen torch, precision ream the hole, then insert a machined and heat treated bolt.

Semi-tubular rivets

A typical technical drawing of an oval head semi-tubular rivet

Semi-tubular
tubular rivets (also known as tubular rivets) are similar to solid rivets, except they have
a partial hole (opposite the head) at the tip. The purpose of this hole is to reduce the amount
of force needed for application by rolling tthe
he tubular portion outward. The force needed to
apply a semitubular rivet is about 1/4 of the amount needed to apply a solid rivet. Tubular
rivets are sometimes preferred for pivot points (a joint where movement is desired) since the
swelling of the rivet is only at the tail. The type of equipment used to apply semi-tubular
semi
rivets range from prototyping tools to fully automated systems. Typical installation tools
(from lowest to highest price) are hand set, manual squeezer, pneumatic squeezer, kick press,
impact riveter, and finally PLC-controlled
controlled robotics. The most common machine is the impact
riveter and the most common use of semitubular rivets is in lighting, brakes, ladders, binders,
HVAC duct work, mechanical products, and electronics. They are offered from 1/16-inch
1/16
(1.6 mm) to 3/8-inch
inch (9.5 mm) in diameter (other sizes are considered highly special) and
can be up to 8 inches (203 mm) long. A wide variety of materials and platings are available,
most common base metals are steel, brass, copper, stainle
stainless,
ss, aluminum and most common
platings are zinc, nickel, brass, tin. Tubular rivets are normally waxed to facilitate proper
assembly. An installed tubular rivet has a head on one side, with a rolled over and exposed
shallow blind hole on the other.

Blind rivets
Three aluminium blind rivets: 1/8", 3/32", and 1/16" Animation of a rivet being tightened
Pop rivet gun with rivet inserted Blind rivets, commonly referred to as "pop" rivets (POP is

School of Mechanical Engineering, K L E Technological University, Hubballi Page 34

 the brand name of the original manufacturer, now owned by Stanley Engineered Fastening, a
division of Stanley Black & Decker) are tubular and are supplied with a mandrel through the
center. The rivet assembly is inserted into a hole drilled through the parts to be joined and a
specially designed tool is used to draw the mandrel into the rivet. This expands the blind end
of the rivet and then the mandrel snaps off. These types of blind rivets have non-locking
non
mandrels and are sometimes avoided for critical structural joints because the mandrels may
fall out, due to vibration
on or other reasons, leaving a hollow rivet that has a lower load-
load
carrying capability than solid rivets. Furthermore, because of the mandrel they are more
prone to failure from corrosion and vibration. Unlike solid rivets, blind rivets can be inserted
and fully installed in a joint from only one side of a part or structure, "blind" to the opposite
side.
Due to this feature, blind rivets are used mainly when access to the joint is available from
only one side. The rivet is placed in a drilled hole and is set by pulling the mandrel head into
the rivet body, expanding the rivet body and causing it to flare against the reverse side. As
the head of the mandrel reaches the face of the blind side material, the pulling force is
resisted, and at a predetermined force
force,, the mandrel snaps at its break point, also called blind
setting. A tight joint formed by the rivet body remains, the head of the mandrel remains
encapsulated at the blind side, although variations of this are available, and the mandrel stem
is ejected.

Prior to the adoption of blind rivets, installation of a solid rivet typically required access to both
sides of the assembly: a rivet hammer on one side and a bucking bar on the other side. In 1916,
Royal Navy reservist and engineer Hamilton Neil Wylie fil
filed
ed a patent for an "improved means of
closing tubularr rivets" (granted May 1917). In 1922 Wylie joined the British aircraft manufacturer
Armstrong-Whitworth
Whitworth Ltd to advise on metal construction techniques; here he continued to
develop his rivet design with a further 1927 patent[5] that incorporated the pull-through
pull through mandrel,
and allowed the rivet to be used blind. By 1928, the George Tucker Eyelet company produced a
"cup" rivet based on the design. It required a separate GKN mandrel and the rivet body to be hhand
assembled prior to use for the building of the Siskin III aircraft. Together with Armstrong-
Armstrong
Whitworth, the Geo. Tucker Co. further modified the rivet design to produce a one-piece
one unit
incorporating mandrel and rivet.[6] This product was later develope
developedd in aluminium and
trademarked as the "POP" rivet. The United Shoe Machinery Co. produced the design in the U.S.
as inventors such as Carl Cherry and Lou Huck experimented with other techniques for expanding

School of Mechanical Engineering, K L E Technological University, Hubballi Page 35

solid rivets.

They are available in flat head, countersunk head, and modified flush head with standard diameters
of 1/8, 5/32 and 3/16 inch. Blind rivets are made from soft aluminum alloy, steel (including
stainless steel), copper, and Monel.

There are also structural blind rivets, which are designed to take shear and tensile loads.

4. Embossing

Figure 14 Embossing Process

Sheet metal embossing is a stamping process for producing raised or sunken designs or relief
in sheet metal. This process can be made by means of matched male and female roller dies,
or by passing sheet or a strip of metal between rolls of the desired pattern. It is often
combined with foil stamping to create a shiny, 3D effect.

Process

School of Mechanical Engineering, K L E Technological University, Hubballi Page 36

 The metal sheet embossing operation is commonly accomplished with a combination of heat
and pressure on the sheet metal, depending on what type of embossing is required.
Theoretically, with any of these procedures, the metal thickness is changed in its
composition.

Metal sheet is drawn through the male and female roller dies,
dies, producing a pattern or design
on the metal sheet. Depending on the roller dies used, different patterns can be produced on
the metal sheet. The pressure and a combination of heat actually "irons" while raising the
level of the image higher than the su
substrate
bstrate to make it smooth. The term "impressing" refers
to an image lowered into the surface of a material, in distinction to an image raised out of the
surface of a material.
In most of the pressure embossing operation machines, the upper roll blocks are stationary,
while the bottom roll blocks are movable. The pressure with which the bottom roll is raised
is referred to as the tonnage capacity.
Embossing machines are generally sized to give 2 inches (5 cm) of strip clearance on each
side of an engraved embossing
bossing roll. Many embossing machines are custom
custom-manufactured,
manufactured, so
there are no industry-standard
standard widths. It is not uncommon to find embossing machines in
operation producing patterns less than 6 inches (15 cm) wide all the way up to machines
producing patterns
erns 70 inches (180 cm) wide or more.

5. Spot wielding

Figure 15 Welding Process

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 Resistance spot welding (RSW) is a process in which contacting metal surface points are
joined by the heat obtained from resistance to electric curr
current.
ent. It is a subset of electric
resistance welding.

Work-pieces
pieces are held together under pressure exerted by electrodes. Typically the sheets are
in the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper
alloy electrodes to concentrate welding current into a small "spot" and to simultaneously
clamp the sheets together. Forcing a large current through the spot will melt the metal and
form the weld. The attractive feature of spot welding is that a lot of energy can be delivered
delivere
to the spot in a very short time (approximately
(approxim 10–100 milliseconds). That permits the
welding to occur without excessive heating of the remainder of the sheet.

The amount of heat (energy) delivered to the spot is determined by the resistance between
thee electrodes and the magnitude and duration
durati of the current. The amount of energy is chosen
to match the sheet's material properties, its thickness, and type of electrodes. Applying too
little energy will not melt the metal or will make a poor weld. Applyin
Applying
g too much energy
will melt too much metal, eject molten material, and mak
makee a hole rather than a weld. Another
feature of spot welding is that the energy delivered to the spot can be controlled to produce
reliable welds.

Projection welding is a modification

on of spot welding. In this process, the weld is localized by
means of raised sections, or projections, on one or both of the workpieces to be joined. Heat
is concentrated at the projections, which permits the welding of heavier sections or the closer
spacing
ing of welds. The projections can also serve as a means of positioning the workpieces.
Projection welding is often used to weld studs, nuts, and other threaded machine parts to
metal plate. It is also frequently used to join crossed wires and bars. This is another high
high-
production process, and multiple projection welds can be arranged by su
suitable
itable designing and
jigging.

Applications
Spot welding is typically used when welding particular types of sheet metal, welded wire
mesh or wire mesh. Thicker stock is mo
more
re difficult to spot weld because the heat flows into
the surrounding metal more easily. Spot welding can be easily identified on many sheet

School of Mechanical Engineering, K L E Technological University, Hubballi Page 38

 metal goods, such as metal buckets. Aluminum alloys can be spot welded, but their much
higher thermal conductivity and electrical conductivity requires higher welding currents.
This requires larger, more powerful, and more expensive welding transformers.

BMW plant in Leipzig, Germany: Spot welding of BMW 3 series car bodies with KUKA
industrial robots.
Perhaps the most
st common application of spot welding is in the automobile manufacturing
industry, where it is used almost universally to weld the sheet metal to form a car. Spot
welders can also be completely automated, and many of the
industrial robots found on assembly
assembly lines are spot welders (the other major use for robots
being painting).

Spot welding is also used in the orthodontist's clinic, where small

small-scale
scale spot welding equipment is
used when resizing metal "molar bands" used in orthodontics.

Another application is spot welding straps to nickel–cadmium,

nickel nickel–metal
metal hydride or Lithium
Lithium-
ion battery cells to make batteries. The cells are joined by spot welding thin nickel straps to the
battery terminals. Spot welding can keep the battery from getting too hot, as might
mig happen if
conventional soldering were done.

Good design practice must always allow for adequate accessibility. Connecting surfaces should be
free of contaminants such as scale, oil, and dirt, to ensure quality welds. Metal thickness is
generally not a factor in determining good welds.

Processing and Equipment

Spot welding involves three stages; the first of which involves the electrodes being brought to the
surface of the metal and applying a slight amount of pressure. The current from the electrodes is
then applied briefly after which the current is removed but the electrodes remain in place for the
material to cool. Weld times range from 0.01 sec to 0.63 sec depending on the thickness of the
metal, the electrode force and the diameter of the electrodes
electrod themselves.

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The equipment used in the spot welding process consists of tool holders and electrodes. The tool
holders function as a mechanism to hold the electrodes firmly in place and also support optional
water hoses that cool the electrodes during we
welding.
lding. Tool holding methods include a paddle-type,
paddle
light duty, universal, and regular offset. The electrodes generally are made of a low resistance
alloy, usually copper, and are designed in many different shapes and sizes depending on the
application needed.

The two materials being welded together are known as the workpieces and must conduct
electricity. The width of the workpieces is limited by the throat length of the welding apparatus
and ranges typically from 5 to 50 inches (13 to 130 cm). Workpiece tthickness
hickness can range from
0.008 to 1.25 inches (0.20 to 32 mm).

After the current is removed from the workpiece, it is cooled via the coolant holes in the center of
the electrodes. Both water and a brine solution may be used as coolants in spot welding
mechanisms.

Electrical notes

The basic spot welder consists of a power supply, an energy storage unit (e.g., a capacitor bank), a
switch, a welding transformer, and the welding electrodes. The energy storage element allows the
welder to deliver high instantaneous
aneous power levels. If the power demands are not high, then the
energy storage element isn't needed. The switch causes the stored energy to be dumped into the
welding transformer. The welding transformer steps down the voltage and steps up the current. An
important feature of the transformer is it reduces the current level that the switch must handle. The
welding electrodes are part of the transformer's secondary circuit. There is also a control box that
manages the switch and may monitor the welding elect
electrode voltage or current.

The resistance presented to the welder is complicated.[7] There is the resistance of secondary
winding, the cables, and the welding electrodes. There is also the contact resistance between
the welding electrodes and the workpiece
workpiece.. There is the resistance of the workpieces, and the
contact resistance between the workpieces.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 40

 At the beginning of the weld, the contact resistances are usually high, so most of the initial
energy will be dissipated there. That heat and the clamping forc
forcee will soften and smooth out
the material at the electrode
electrode-material
material interface and make better contact (that is, lower the
contact resistance). Consequently, more electrical energy will go into the workpiece and the
junction resistance of the two workpieces
workpieces.. As electrical energy is delivered to the weld and
causes the temperature to rise, the electrodes and the workpiece are conducting that heat
away. The goal is to apply enough energy so that a portion of material within the spot melts
without having the entire
tire spot melt. The perimeter of the spot will conduct away a lot of heat
and keep the perimeter at a lower temperature. The interior of the spot has less heat
conducted away, so it melts first. If the welding current is applied too long, the entire spot
melts,
elts, the material runs out or otherwise fails, and the "weld" becomes a hole.

The voltage needed for welding depends on the resistance of the material to be welded, the
sheet thickness and desired size of the nugget. When welding a common combination like
lik
1.0 + 1.0 mm sheet steel, the voltage between the electrodes is only about 1.5 V at the start
of the weld but can fall as low as 1 V at the end of the weld. This decrease in voltage results
from the reduction in resistance caused by the workpiece melting.
melting. The open circuit voltage
from the transformer is higher than this, typically in the 5 to 22 volt range.[8]

The resistance of the weld spot changes as it flows and liquefies. Modern welding equipment
can monitor and adjust the weld in real-time
real to ensure a consistent weld. The equipment may
seek to control different variables during the weld, such as current, voltage, power, or
energy.

Welder sizes range from 5 to 500 kVA.[9] Micro spot welders, used in a variety of
industries, can go down to 1.5 kVA or less for precision welding needs.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 41

 6. Hemming

Figure 16 Hemming Process

Hemming metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming
is the process in which the edge is rolled flush to itself,
itself, while a seam joins the edges of two
materials.

Hems are commonly used to reinforce an edge, hide burrs and rough edges, and improve
appearance.

Seams are commonly used in the food industry on canned goods, on amusement park cars, in metal
roofing (with
th a roof seamer), and in the automotive industry.

Process
The process for both hemming and seaming are the same, except that the tonnage requirement is
greater for seaming. The process starts by bending the edge to an acute angle. A flattening die is
then used to flatten the hem.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 42

 Findings and Recommendations

1. DC motor assembly fixture for Aerostation hood:

Aerostation
erostation is a 3 in 1 hood wi
with built in air purifier and blower,, the issue was regarding the
assembly of the DC motor blower which was to be mounted on the hood. The fixture was
made considering the orientation and distance between the slot in the hood and blower.

Figure 17 Actual Fixture image

2. Fixture design for Frameless cook top glass pasting:

School of Mechanical Engineering, K L E Technological University, Hubballi Page 43

 Figure 18 Glass pasting fixture

Design and fabricate the fixture to paste bevel glass on frameless cook top glass.

3. Fixture design for Supreme 3 burner frame:

Figure 19 Supreme 3b Frame fixture

4. Design
sign of aluminum pipes for 3 & 4 Burner Supreme cook top:

School of Mechanical Engineering, K L E Technological University, Hubballi Page 44

 Figure 20 Al pipe for 3 & 4 Supreme cook top

5. Fixture for faber logo pasting on the duct of the hood:

Figure 21 CAD model of fixture

6. Glass
ass drawing for supreme 3 & 4 Burner cook top:

Figure 22 CAD model of glass

School of Mechanical Engineering, K L E Technological University, Hubballi Page 45

 7. Cook Top Frame Development

Figure 23 CAD model of the cook top

Work experience
Gained valuable work experience the hands-on
on work experience received is invaluable and
cannot be obtained in a classroom setting. We have the opportunity to apply acquired
knowledge to real work experiences, witnessing firsthand the day
day-to-day
day job duties they can
expect to encounter in their chosen
hosen field. In addition to learning the specialized skills of a
particular field, transferable skills such as communication, teamwork, and computer
proficiency are also obtained in an internship, fully preparing interns to enter the workforce
upon graduation.
ion. I have explored my career path and internships is a great way to acquaint
myself with the field of interest. Taking on an internship while in college allowed me to
work in their desired field, helping them decide if the field is right for me or not. By
B doing
this internship I feel confident that I have chosen the right degree to start my career..

REFERENCES

 faberindia.com

School of Mechanical Engineering, K L E Technological University, Hubballi Page 46