1. ARYA COLLEGE OF ENGINEERING & INFORMATION TECHNOLOGY
Industrial Training Report
at
NEEL METAL PRODUTS LIMITED
MANESAR
Submitted To:- Submit By:-
Prof Arun Kumar Arya Hitesh Pathak
(Head of Mechanical Department) 11EARME044
B. Tech Mechanical
4th Year

2. ACKNOWLEDGEMENT
It is indeed a great pleasure and privilege to present this report on training at NEEL METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.
I am extremely grateful to my Head of Department and training and placement officer for issuing a Training letter, which made my training possible at NEEL METAL PRODUCTS LIMITED, JBM GROUP, MANESAR.
First, I thank The HR Head, MR. Gaurav Saraswat for considering my potential in doing this training and providing this wonderful opportunity.
I would like to express my gratitude to MR. Rakesh Kumar for his invaluable suggestions, motivation, guidance and support throughout the training. His methodology to start from simple ant then deepen through made me to bring out this project report without anxiety.
Thanks to all other JBM officials, operators and all other members of JBM, yet uncounted for their help in completing the project and see the light of success. I am very thankful to friends, colleagues and all other persons who rendered their assistance directly or indirectly to complete this project work successfully.
Dated- July 2014 Hitesh Pathak

3. About Company:-
JBM Group began its journey of excellence in 1983. The organization commenced operations as a manufacturer of LPG Cylinders for the Delhi-NCR region of India. Moving strength to strength, assisted with experience and knowledge, JBM Group entered into the automotive industry in 1985.
In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the manufacturing of sheet metal components and assemblies. The journey began with a vision to expand the business in the automotive sector by keeping abreast with market trends and global technology.
Headquartered at Delhi-NCR, JBM Group is a diversified conglomerate with presence in automotive, engineering & design services, renewable energy and education sectors. The organization’s commitment towards all stakeholders and community has made it a leading manufacturing and engineering player.
The milestones and achievements of JBM Group gave the energy for diversification and establishment of multiple business units in order to meet the needs of customers. The organization’s management follow a unique business model to create empowered companies that enjoy the best of entrepreneurial independence, assisted with leverage of group-wide synergies.
Overview:-
JBM Group is a focused, dynamic and progressive organization that provides customers with value added products, services and innovative solutions. The Group has a diversified portfolio to serve in the field of automotive, engineering & design services, renewable energy and education sectors and

4. has an infrastructure of 35 manufacturing plants, 4 engineering & design centres across 18 locations globally.
With turnover of USD 1.2 billion, JBM Group has broadened its horizons by focusing on quality delivery, solutions approach, product development processes, flexible manufacturing systems and contract manufacturing.
JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd, Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and many more.
The Group has alliances with more than 20 renowned companies globally and the associations include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel Corporation, Magnetto (CLN Group), Ogihara, Sumitomo and many more. The organization’s structure enables each business unit to chart its own future and simultaneously leverage synergies across its competencies.

5. Introduction to the Company
Company Profile:-
Name: JAY BHARAT MARUTI LTD.
Division: NEEL METAL PRODUCTS LIMITED, MANESAR
Head Quarters: DELHI
Established: 1983
Turnover: Rs.4500 Crores(overall)
Employees (No.): AROUND 15,000
Introduction:-
The Neel Metal Products Limited, Manesar is a major vendor company of Honda 2 Wheelers India Ltd. Neel Metal Products Ltd. (NMPL) is the fastest growing Company of JBM Group with high-tech plants at various locations in

6. India. NMPL has earned a leading position in industry with facilities available in press lines up to 1200 tons, weld lines and ED coating plant- which are not only limited to auto world but also fitting for white goods industry.
Vision:-
“Expanding leadership in our business through people, keeping pace with market trends and technology.”
Core Values:-
We believe in...
Simplicity, by keeping a low profile externally and having clear, open and effective communication within the organization.
Teamwork, with well-defined responsibilities and accountability.
Relationships of trust amongst people, through well-defined job responsibility and authority.
According top priority to customer focus, through prompt and appropriate response.
Respect and care for all those dedicated to meeting commitments.
Technology:-
Technology, Innovation and People serve as the 3 key pillars of the JBM foundation. Core to this philosophy is a constant quest for excellence by enhancing technology, enabling innovation and empowering people, thereby, creating consistent value for all stakeholders.
JBM Group has always kept a close watch on the dynamic needs of its customers and continues the journey of efficiency by enhancing the

7. technology at every stage. The organization has collaborated with best global technology partners; possess state-of-the-art manufacturing facilities and highly automated processes. These advantages have established new benchmarks that have aided in providing superior quality and flawless technical perfection to the organization's deliverables.
The continuous commitment towards excellence and consistent efforts to innovate have brought excellent growth results for the Group. Apart from incorporating sophisticated technology, JBM Group aims to not only exceed expectations, but to create value through innovation. The long standing commitment to nurture research and development has brought the organization a long way since its commencement 3 decades ago.
Environment, Health & Safety:-
At JBM, sustainability is the way of doing business. The Group aligned its goals for environment, health and safety, making an impact across its value chain worldwide. Together with the suppliers, customers and stakeholders, JBM strives to maintain highest standards to preserve and protect the environment, as well as enhance the health and safety of the Group’s employees and communities.
Departments in Neel Metal Products Limited, Manesar:-
1) Paint shop
2) Weld shop
3) Press Shop
4) Quality department
5) Engineering department
6) IT department

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

9. Production:-
Production is defined by the Webster online as “to make into a product suitable to use.”
The action of manufacturing from components or raw material or the process if being so produced.
Production is a process of combining various material inputs and immaterial inputs in order to make something for consumption. It is the act of creating output, a good or service which has value and contributes to the utility of individuals. Economic well-being is created in a production process, meaning of all economic activities that aim directly or indirectly to satisfy human needs. The degree to which the needs are satisfied is often accepted as a measure of economic well-being.
Types of Production Procedure:-
Casting Process:- This type of procedure required liquid material. This is the only process which uses liquid material. This is oldest procedure of production in which the molten metal is poured into refractory mould cavity and allowed to solidify. The object from the cavity removed after the solidification.
Forming Process:- This solid state production process involving minimum amount of material wastage. In this process the metal may be heated to a
Suppliers
 Material
 Energy
 Capital
 Service
Company
(Production)
Customers
 Households
 Other Products

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

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

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

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

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

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

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

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

18. pieces. The heat generated depends on the electrical resistance and thermal conductivity of the metal, and the time that the current is applied. The heat generated is expressed by the equation:
E=I2*R*t
Where E is the heat energy, I is the current, R is the electrical resistance and t is the time that the current is applied.
Copper is used for electrodes because it has a low resistance and high thermal conductivity compared to most metals. This ensures that the heat is generated in the work pieces instead of the electrodes.
Materials suitable for spot welding:-
Steel has a higher electrical resistivity and lower thermal conductivity than the copper electrodes, making welding relatively easy. Low carbon steel is most suitable for spot welding. Higher carbon content or alloy steel tends to form hard welds that are brittle and could crack. Aluminium has an electrical resistivity and thermal conductivity that is closer to that of copper. However, aluminium's melting point is much lower than that of copper, making welding possible. Higher levels of current must be used for welding aluminium because of its low resistivity.
Galvanized steel (i.e. steel coated with zinc to prevent corrosion) requires a different welding approach than uncoated steel. The zinc coating must first be melted off before the steel is joined. Zinc has a low melting point, so a pulse of current before welding will accomplish this. During the weld, the zinc can

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

20. Diameter of the electrode contact surface:-
One general criterion of resistance spot-welding is that the weld shall have a nugget diameter of 5*t1/2, “t” being the thickness of the steel sheet. Thus, a spot weld made in two sheets, each 1 mm in thickness, would generate a nugget 5 mm in diameter according to the 5*t½-rule. Diameter of the electrode contact surface should be slightly larger than the nugget diameter. For example, spot welding two sheets of 1 mm thickness would require an electrode with a contact diameter of 6 mm. In practice, an electrode with a contact diameter of 6 mm is standard for sheet thickness of 0.5 to 1.25 mm. This contact diameter of 6 mm conforms to the ISO standard for new electrodes.
Squeeze time:-
Squeeze Time is the time interval between the initial application of the electrode force on the work and the first application of current. Squeeze time is necessary to delay the weld current until the electrode force has attained the desired level.
Weld time:-
Weld time is the time during which welding current is applied to the metal sheets. The weld time is measured and adjusted in cycles of line voltage as are all timing functions. One cycle is 1/50 of a second in a 50 Hz power system. (When the weld time is taken from American literature, the number of cycles has to be reduced due to the higher frequency (60Hz) that is used in the USA.)
As the weld time is, more or less, related to what is required for the weld spot, it is difficult to give an exact value of the optimum weld time. For instance:
Weld time should be as short as possible.

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

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

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

24. 2. In second step of PDI we test the strength of joint via performing stretch test. Scratch and Roundness of edges and corner also perform again here.
3. Then Chain case will send for Painting.
The whole procedure of making Chain Case will take 20 seconds to complete with PDI. Making process of Right and Left Part has been done parallel. The annual defects of the pieces are 2% of total.
Precaution to take in Joining:-
1. Do not stop the part at a same place.
2. Do not perform welding without wearing gloves.
3. Do the work at same rate as guided.
4. Always wear an apron before start working.
5. Always follow the rules of workshop.
6. In case of any hazard contact to supervisor and medical officer.
Conclusion of Project:-
Joining procedure of Chain Case of Honda Unicorn has been completed. The total find error is 5% on my work.

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

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

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

28. Preparations for the Painting Procedure:-
1. For the Hot Water Rinse: Here we take a sump tank for containing of water than we heat that up to 40 to 60˚C with maintaining of 0.5 to 1.2 Kg/cm2 pressure. Here we take normal water which is usually available.
2. For Knock of Degreasing: Here we take a cleaning chemical in a tank and maintain 40 to 60˚C temperature, 0.5 to 1.2 Kg/cm2 pressure and alkalinity 30 to 35 ml.
3. For Degreasing: Here we again maintain the cleaning chemical condition as Knock of Degreasing.
4. For Water Rinse 1: Here we take water in a tank and maintain pressure at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.
5. For Water Rinse 2: Here we again take water in tank and maintain pressure at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 9.0.
6. For Surface Activation: Here we take a special chemical in tank for that maintains pressure at 0.5 to 1.0 Kg/cm2 and pH value at 8.0 to 10.0.
7. For Phosphatising: We take a coat of phosphate for that maintain pressure at 0.8 to 1.0 Kg/cm2, Temperature at 40 to 50˚C, Total Acidity 20 to 24 ml, Free Acidity 0.6 to 0.8 ml and Tonner Value at 2 to 4 ml.
8. For DM Rinse 1: We take water in tank and maintain pressure at 0.5 to 1.0 Kg/cm2 and pH value at 5 to 6.
9. For DM Rinse 2: We take water in tank and maintain pressure at 0.5 to 1.0 Kg/cm2 and pH value at 6.5 to 7.0.
10. For Dry off Oven: Maintain Temperature at 90 to 100˚C.
11. For Coating: A spray paint equipment is required and Water-Grease Solution to prevent walls from Coat.
12. For Paint Baking Oven: Maintain Temperature at 130 to 140˚C.

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

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

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

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

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

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

35. Coat Type
Ford Viscosity Cup Value
Primer Coat
15-18 sec
Base Coat
17-20 sec
Top Coat
15 sec
Pre Discharge Inspection of Painted Parts:-
This PDI involves two steps of inspection:-
1. First check every side that should be painted uniformly.
2. Check every side carefully no scratch should be there.
3. If any problem occurs then part should be again hanging in TAG RAG.
Precaution to take in Painting:-
1. Hang parts on hanger carefully.
2. All the tests must be performed after regular time interval.
3. Carefully check every part in TAG RAG chamber
4. Every Part should be unloaded carefully
5. Every movement must be like the last movement of spray gun in the coating chamber.
6. Heating Chambers should be clean by HNO3 after every rest of machine.
Total annual error in painting of Chain Case and Connecting Rod is 0.2%.
Conclusion of Project:-
Painting procedure of the Chain Case of Honda Unicorn and Connecting Rod of Honda Unicorn and Honda Activa is completed. No error was found in working procedure.

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

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

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

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

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

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

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

43. Easy to learn
Disadvantages of MIG welding:-
MIG welding can only be used on thin to medium thick metals
The use of an inert gas makes this type of welding less portable than arc welding which requires no external source of shielding gas
Produces a somewhat sloppier and less controlled weld as compared to TIG (Tungsten Inert Gas Welding)
Parts:-
1. Holder
2. Cable Tie
3. R Pipe
4. Straight Pipe
5. Stay
6. Patgn (Thick and Thin)
7. Gusset Stay
8. MIG Welding
Methodology:-
1. First step all the sheets of metal is procured from the vendor
2. The grade of the material is checked by the inspection department. In inspection these three things are checked. Wrong size of the metal sheet, grade of the metal sheet and the visual defects of the metal sheet.
3. After this all inspection Gusset Holder will join with R Pipe and Straight Pipe.
4. In next step Patgn will join with upper made assembly.
5. Further Stay will join with made assembly.

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

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

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

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

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

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

50. Methodology:-
ERW Steel 2 is used to make frame which has
Thickness = 2.60 mm, 1.60 mm
Diameter = 38.10 mm
Length = 929 mm
1. First step all the sheets of metal is procured from the vendor.
2. The grade of the material is checked by the inspection department. In inspection these three things are checked. Wrong size of the metal pipe, grade of the metal pipe and the visual defects of the metal pipe.
3. In after inspection step pipe is bended via Bending Machine which is made by YLM Taiwan. It is a computer operated system. This machine used Hydraulic energy for Clamping, Holding and Pressing. The pressure is used to bend this pipe is 110 Kg/cm2 with maximum tolerance of 1 mm. Here pipe is bended to a pre defined shape. Honda Avtiva has underbone type of frame.
4. After bending the pipe sanded to Milling Section. In this section milling section Drill holes in it during the drill operation water is used as coolant.
5. Than operation performed pipe sanded for Grinding Operation. In this section Grinder wheel is used to finish surface and remove extra material from pipe.
6. In next step of assembly a Rod opener and centre cross welding has to be done.
7. Then this prepared pipe sanded for the assembly. In first step of assembly pipe is pivoted and under covered.

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

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

53. Conclusion
It’s always a great opportunity to experience the valuable exposure of an industry. There is lot of difference between the Theories and Practices. This Training enables me to understand the aspects of professional life. I like the working environment followed at NEEL METAL PRODUCTS LTD. and come to know how to deal with our colleagues. The company’s members are well cultured & well mannered.
An effective process is followed at NEEL METAL PRODUCTS LTD. but it would become more valuable and impressive by implementing certain efficient measures. The company is constantly focusing on providing better services, quality and reliability to customers, and running successfully in this era of competition.