INTERNSHIP REPORT

1.3 OBJECTIVE OF THIS INTERNSHIP:

The objective of this internship is to know how the manufacturing of car parts takes
place and learn the safety precautions to be taken in a industry, It also includes,

* Study of metal pressing or stamping system

* Study of mash seam welding system

* Study of time management at intermediate stations

* Study of cars body and paint job

* Study of maintenance and servicing

* Study the quality control techniques

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1.4 PRODUCTS MANUFACTURED BY THE COMPANY:

1) BUMPER BEAMS:

Sungwoo Hitech patented the roll forming technology, and has allowed us to create
bumper beams that have proven to be superior in many ways. These parts now weigh
less and cost less than before. Strength and stability is gained through the use of high
strength steel ensuring that our bumper beams have excellent results in crash test.

2) DOORS:

The doors are made by using steel which is further machined using stamping
technique and different techniques as hemming, TWB technology etc, these products
are both lighter and stronger. Precision technologies are utilized to achieve the desired
finish.

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3) HOOD:

Known alternatively and bonnet, this is the opening or closing panel that forms the
upper part of the engine housing.

4) DASH FRAME:

Dash is an part that divides the passenger area and the engine housing area. It prevents
the noise and turbulence and reduces the dust. It even has space to hold things on it.

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5)CENTER FLOOR FRAME:

This product makes up the central floor of the vehicle. It connects the center of the
vehicle to the both front and rear. It is constructed using TWB method Mash-Seam
welding.

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CHAPTER-2

INDUSTRIAL SAFETY

2.1 SAFETY PRECAUTIONS TO BE TAKEN BEFORE

ENTERING THE PLANT:

* Safety helmet is required but Positive Thoughts are important

* Safety goggles are required but conscious vision is important

* Safety hand gloves are required but righteous protective action is important

* Safety shoes are required but quick and safe steps are important means safety
equipment's are required.

2.2 SAFETY SIGNS AND BILL BOARDS:

 Danger Signs – Indicate immediate hazards that will result in injury or death
if not avoided.

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 Warning Signs – Indicate a hazard level that falls somewhere between

caution and danger, indicating a risk that could result in serious injury or death
if not avoided.

 Caution Signs – Represent the lowest hazard level, indicating potentially

hazardous situations that may result in minor to moderate injury if not avoided.

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CHAPTER-3

MACHINERY USED IN PLANT:

1) CONVEYER BELTS:

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to
belt conveyor). A belt conveyor system is one of many types of conveyor systems. A
belt conveyor system consists of two or more pulleys (sometimes referred to as
drums), with an endless loop of carrying medium—the conveyor belt—that rotates
about them. One or both of the pulleys are powered, moving the belt and the material
on the belt forward. The powered pulley is called the drive pulley while the un
powered pulley is called the idler pulley. There are two main industrial classes of belt
conveyors; Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large
volumes of resources and agricultural materials, such as grain, salt, coal, ore, sand,
and more.

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2) WELDING ROBOT:

Robot welding is the use of mechanized programmable tools (robots), which

completely automate a welding process by both performing the weld and handling the
part. Processes such as gas metal arc welding, while often automated, are not
necessarily equivalent to robot welding, since a human operator sometimes prepares
the materials to be welded. Robot welding is commonly used for resistance spot
welding and arc welding in high production applications, such as the automotive
industry.

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3) PAINTING ROBOT:

Originally industrial paint robots were large and expensive, but robot prices have
come down to the point that general industry can now afford the same level of
automation used by the large automotive manufacturers. Painting robots generally
have five or six axis motion, three for the base motions and up to three for applicator
orientation. These robots can be used in any explosion hazard Class 1 Division 1
environment.

OVER HAED CONVEYER:

This type of conveyor gets its name from where it is normally found in a plant,
factory or warehouse – overhead. Overhead conveyors utilize the unused open space
above machines and people.

4) CNC MACHINE:

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Numerical control (also computer numerical control, and commonly called CNC) is
the automated control of machining tools (such as drills, boring tools, lathes) and 3D
printers by means of a computer. A CNC machine processes a piece of material
(metal, plastic, wood, ceramic, or composite) to meet specifications by following a
coded programmed instruction and without a manual operator.

5) JIG WELDING MACHINE:

A jig is a large brace that keeps a welding project stable in the face of pressure, heat,
motion, and force. A quality jig will streamline welding work by keeping parts
together in a vice grip. Whether the welding is entirely manual, partially automatic, or
fully robotic, a jig moves the work-piece while the tool remains stationary.

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6) Air wrench:

An impact wrench (also known as an impact, impact gun, air wrench, air gun, rattle
gun, torque gun, windy gun) is a socket wrench power tool designed to deliver high
torque output with minimal exertion by the user, by storing energy in a rotating mass,
then delivering it suddenly to the output shaft.

7) STAMPING DIE:

stamping (also known as pressing) is the process of placing flat sheet metal in either
blank or coil form into a stamping press where a tool and die surface forms the metal
into a net shape. Stamping includes a variety of sheet-metal forming manufacturing
processes, such as punching using a machine press or stamping press, blanking,
embossing, bending, flanging, and coining.This could be a single stage operation
where every stroke of the press produces the desired form on the sheet metal part, or
could occur through a series of stages. The process is usually carried out on sheet
metal, but can also be used on other materials, such as polystyrene.

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CHAPTER-4

WORK SHOP:

4.1 PRODUCTION PROCESSES:

1) UNLOADING COILS:

The coils imported from a company are unloaded to a storage space in side a ware-
house through a over head crane and conveyor systems. Then from ware-house these
coils are taken for further processes and manufacturing purpose. This metal sheet coil
is the raw material for manufacturing parts.

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2) SLITTING LINE:

slitting lines feature very stiff slitter heads with no axial gaps, shafts perfectly parallel
and minimum bending in rotation, which together with the correct definition of the
slits back tension device, able to supply high and even recoiling tension without
marks or scratches on the surface or the edges, are the necessary combination for a
world class slitting line.

3) BLANKING LINE:

Blanking lines are commonly used in the automotive industry, for the production of
car body and structural parts. They therefore require high production capacity
combined with high quality of the produced blank, especially for car body parts that
need to be stamped thereafter. Expansions for processing aluminum and high-strength
steel can be integrated easily.

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4) WELDING LINE:

Gas Metal Arc Welding (GMAW welding) on pipe. Welding is a fabrication process
that joins materials, usually metals or thermoplastics, by using high heat to melt the
parts together and allowing them to cool, causing fusion.

 MASH SEAM WELDING:

Mash welding is a variant of resistance seam welding in which the sheets to be joined
are overlapped by a distance of only about 1.5 times the sheet thickness (t). The face
of the welding wheel is wider than this contact width and during welding the material
is crushed to a final thickness typically 1.4t. Some melting occurs, but the edges of the
joint form a solid phase bond to eliminate the crevice.

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 REMOTE WELDING SYSTEM:

Remote welding system consists of a gantry-style multi-axis motion system and a

beam scanning head. A long focal length is used for laser welding, which allows the
distance between the beam manipulating element and the workpiece to be as large as
4-5 ft typically.

5) FORMING LINE:

Roll forming lines can be set up with multiple configurations to punch and cut off
parts in a continuous operation. For cutting a part to length, the lines can be set up to
use a pre-cut die where a single blank runs through the roll mill, or a post-cut die
where the profile is cutoff after the roll forming process.

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 PRESS LINE:

Stamping includes a variety of sheet-metal forming manufacturing processes, such as

punching using a machine press or stamping press, blanking, embossing, bending,
flanging, and coining. This could be a single stage operation where every stroke of the
press produces the desired form on the sheet metal part, or could occur through a
series of stages.

6) ASSEMBLY LINE:

An assembly line is a manufacturing process (often called a progressive assembly) in

which parts (usually interchangeable parts) are added as the semi-finished assembly
moves from workstation to workstation where the parts are added in sequence until
the final assembly is produced.

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7) ELECTRODE DEPOSITION COATING:

Electro deposition is the process of coating a thin layer of one metal on top of a
different metal to modify its surface properties. Done to achieve the desired electrical
and corrosion resistance, reduce wear&friction, improve heat tolerance and for
decoration.

8) SHIPPING:

The term shipping originally referred to transport by sea but in American English, it
has been extended to refer to transport by land or air (International English:
"carriage") as well. "Logistics", a term borrowed from the military environment, is
also used in the same sense.

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CHAPTER-5

5.1 MANUFACTURING OF A CAR DOOR:

It all starts with carbon, steel and alloy that is strong and it is malleable, now
machinery straightens it. A large blade slices it to the desired length producing sheets
called blanks. And then it's over to a powerful press. This particular one is a trial press
which offers a better view of the process than the one on the production line.

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The press forces the blank into a die, giving it the basic shape of two corridors. It's a
design that's been engineered for both aerodynamics and strength. Back on the
production line, the main press is churning out car doors, an automated device with
fingers then grips the newly shaved steel and transfers it to a punch cutter. It separates
the two doors and trims the excess metal from the edges. With the outer door panels
now complete, the handler inspects them for bumps, dents or scratches, he approves
only those that are absolutely flawless.

The next worker arranges the window frames, a reinforcing plate for the hinge and the
inner door panel, all in a special clamping fixture. Its fingers grip the parts to hold
them in position as the fixture rotates and two robots move in to weld them together.
At the next station, the worker arranges steel bars and tubes on a robotic platform,
they add strength to the door so it will better withstand any impact. He places the
inner door panel over the bars and tubes.

The robotic platform angles the parts for welding. Another robot applies adhesive to
the rim of the outer door panel. More robots, apply adhesive at strategic locations and
those that match up to the tubes and bars on the inner panel as they made it to the
outer one. A special press then folds the lip of the outer panel over the inner one. This
hemming gives the assembled car door a neat orange. We're back with the inner and
outer panels now, joined the corridor, undergoes rust proofing paint and other
protective treatments.

Hemming is a technology used in the automotive industry to join inner and outer
closure panels together (hoods, doors, tailgates, etc.). It is the process of
bending/folding the flange of the outer panel over the inner one. The accuracy of the
operation significantly affects the appearance of the car’s outer surfaces and is
therefore a critical factor in the final quality of a finished vehicle.

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Now, over on the assembly line, a worker fits the handle into its knees and bolted to
the door from the other side. Chrome trim is clipped into place. Moving down the
line, a worker installs a small fixed window in the groove of the frame, uses a plastic
protector to prevent scratches as he slides the larger window into its slot in the door
and links it to a power lifting mechanism inside. He separates the two windows with a
metal divider at the next station.

This car door gets an automated side view mirror and they're now ready for the inner
panel and its workings. The employee wires the panel to the door and snaps it into
place. He tests the power windows and they close to a tight seal indicating a
successful installation. A special elevator now lowers the completed car doors six
meters to the next station.

5.2 MANUFACTURING OF A CAR HOOD:

The invention discloses a manufacturing process of a car hood, and relates to the field
of car manufacturing. The manufacturing process comprises the following steps: (1)
blanking, (2) stretch forming, (3) trimming and punching, (4) deburring, (5) welding,

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(6) grinding, (7) painting, (8) baking, (9) polishing and waxing, and (10) coating.
According to the manufacturing process, an outer cover plate and an inner cover plate
similar in shape are designed to use the same blanking die for blanking so as to reduce
the production cost; a compound die with trimming and punching functions is adopted
to reduce the steps and improve the production efficiency; a numerical control
automatic resistance spot welding machine is used for welding the hood, so that the
welding efficiency and accuracy are improved; an acrylic paint is used for repeatedly
spraying the hood for three times, so that the paint layer has strong adhesive force and
good heat resistance; the coating processing is used to improve the oxidation, high
temperature and scratch resistances of the hood paint.

5.2.1 IN DETAIL PROCESS:

A manufacturing process for automobile engine cover, bonnet is divided into outer
cover plate and inner cover plate two pieces, it is characterized in that, comprises the
steps:

(1) Blanking: be placed on blanking die by manufacturing the sheet material of

bonnet, stamping-out goes out suitable blank shape, and blanking pressure gets 52KN
to 80KN, and outer cover plate is identical with the blank shape of inner cover plate.

(2) Stretch Forming: the blank gone out by stamping-out is placed on two groups of
different stretching dies, and stretch forming goes out the blank of outer cover plate
and inner cover plate respectively, and tensile force gets 50KN to 65KN.

(3) Edge-cutting and hole-punching: the outer cover plate after stretch forming and
inner cover plate are placed on respectively on corresponding trimming and piercing
die, carry out trimming shaping and piercing and shaping die, draw accurate overall
size, blanking pressure gets 46KN to 68KN.

(4) Deburring: outer cover plate and inner cover plate are arranged on corresponding
stationary fixture respectively, uses sander to get rid of the punching burr of outer
cover plate and inner cover plate.

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(5) Weld: outer cover plate and inner cover plate are combined, and is fixed by
fixture, use numerical control automatic resistance mash welder outer cover plate and
inner cover plate to be welded together.

(6) Polish: use sander to be ground off by the welding burr of bonnet, then bonnet
outer surface is polished flat, make the surface roughness of bonnet reach between
Ra0.8 to Ra1.6.

(7) Spray Paint: polished bonnet is placed into combined padding and drying system,
then bonnet is sprayed paint process, repeatedly spray paint 3 to 5 times.

(8) Toast: the bonnet handled well spraying paint carries out baking process in
combined padding and drying system, adopts high temperature baking varnish
method, heat lamp temperature is set between 280 DEG C to 400 DEG C, toasts and
taken out by bonnet after 1 to 4 hour.

(9) Polishing waxing: use polishing machine by the polishing of bonnet upper surface,
re-uses wax-polishing machine and carries out waxing process to bonnet polishing
place.

(10) Plated Film: use spray gun special, uniformly sprays coated product on car paint
surface, then adopts spiral smearing method that liquid liquid is evenly coated on
vehicle body with special sponge, finally carries out wiping examination with cotton
towel.

CHAPTER-6

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Internship Summary:

The Sungwoo Hitech industry or the plant has some set of rules to follow before
entering the work area. All the people are educated about the signs and bill boards that
are being used in the premises of the plant. The manufacturing process comprises the
following steps blanking, stretch forming, trimming and punching, deburring,
welding, grinding, painting, baking, polishing and waxing, and coating. Different
types of machinery that are used in the plant are conveyor belts, welding robots,
painting robots, over head crane, jig welders, air wrench, stamping dies, etc., The
product processing line from the start goes as follows unloading the coils - slitting line
- blanking line - welding line - forming line - press line - assembly line - electrode
deposition coating - shipping the parts that are manufactured to the alliance company
which are in need of the products companies such as KIA MOTORS, HYUNDAI.
Each part being manufactured will have a spare of 12 sets to avoid the penalty that
will be imposed on the sungwoo hitech company if there is any delay in the supply of
the parts to the alliance company.

6.1 Conclusion

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It is known that practical experience is the best, and internships give students that
hands-on experience they need. I feel that quality internships are essential to develop
key skills that you can't get in a classroom. Skills such as multitasking,
communicating, learning to deal with diversity, and dealing with deadlines are
different when you are working for someone else, not yourself like you do in college.
Internships are also a great way to network with people in the industry.

The course of this internship has helped to get similar with various Machining
processes, production and also the safety measures to be taken in an industry. It has
provided good understanding of the different phases involved in a car production the
time management, and knowledge about the industry infrastructure.

BIBLIOGRAPHY:

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1) https://www.swhitechco.m.ech21.com
2) https://www.wikipedia.com

3) https://www.sungwoohitech.com

4) https://www.ford.com

5) https://www.slideshare.net

6) Advance machining processes: nontraditional & hybrid machining processes by:

ABDEL-GAWAD

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