INDEX

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CONTENTS

1. ACKNOWLEDGEMENT

2. ABSRACT

3. ABOUT THE ORGANISATION

3.1 BHARAT FOGRE LTD. PRODUCTS

3.2 VARIOUS CUSTOMERS

4. VARIOUS DEPARTMENTS IN BFL

4.1 PRODUCTION DIVISION

4.1.1 FORGE MODERNIZATION DIVISION I

4.1.2 FORGE MODERNIZATION DIVISION II

4.1.3 FORGE MODERNIZATION DIVISION III

4.1.4 HEAVY FORGE DIVISION I & II

4.1.5 A2 LINE

4.1.6 FORGE SHOP

4.1.7 HEAT TREATMENT DIVISION

4.1.8 MACHINED COMPONENT DIVISION I & II

4.2 DESIGN AND QUALITY CONTROL

4.2.1 CLOSED DIE FORGING DIVISION

4.2.2 METTALLURGICAL QUALITY CONTROL

4.2.3 DIE SHOP

4.3 CORPORATE OFFICE DEPARTMENTS

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4.3.1 PRODUCTION AND PLANNING CONTROL

4.3.2 SALES

4.3.3 INTERNATIONAL TRADE DIVISION

4.3.4 MATERIALS

4.3.5 FINANCE

4.4 OTHER DEPARTMENTS

4.4.1 ENVIRONMENTAL ENGG. & CIVIL DEPT.

4.4.2 MACHINE TOOL BUILDING

4.4.3 SAFETY DEPARTMENT

5. SUMMERY

ACKNOWLEDGEMENT

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We take this opportunity to thank Mr. B.N. Kalyani, chief managing director, Bharat forge

ltd. And Kalyani group of companies for providing the opportunity to undergo and In-plant

training programme in the reputed organization.

We would also like to thank Mrs. Leena Deshpande for their eminent guidance during the

session and help us to understand the group and various regulations.

We also thankful to Mrs. Shobha Ronimath & Ms. Hemange for helping us with the

process for HR and their support for various project related difficulties.

We also thankful to the shop floor in-charges, officers and workman for their help in

understanding new processes in the industry. They made sure that we could get all the info

they could possibly share.

We are also thankful to our college D.K.T.E. Society’s Textile and Engineering Institute,

Ichalkaranji and Head of Department of Mechanical Engineering, Dr. V.R. Naik for

providing us with this golden opportunity of learning, in a prestigious industry.

Thanks to all those who directly or indirectly helped us in the successful completion of our

summer training.

JAYDEEP D. SAHUTE

CHETANKUMAR B. SUTAR

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ABSTRACT

We had wonderful opportunity of understanding the working of an industry and various

activities that are carried out during our training at ‘Bharat Forge Ltd. Pune’

This ‘induction training report’ that we present before you, gives the description of various

departments seen during the training. This report contains information of the activities we

came to know about during our 15 days of summer training. It also includes induction

program and departmental introduction.

First section is about the company profile which includes information related to the company

history, its present market status and the product range description. Next section illustrates

different departments that are responsible for the proper and efficient functioning of the

company. Information about the functions and the procedure of the various departments that

we were able to undergo training has been included.

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ABOUT THE ORGANISATION

Bharat Forge Limited (BFL),Pune, a technology driven global leader in metal forming

havingtrans‐continental presence on more than a dozen manufacturing locations and serving

several sectors including automobile, railways, shipping, oil and gas, aerospace, etc. is

staging a comprehensive foray into power sector

Part of Kalyani Group – a US$ 2.4 bn conglomerate with more than US $ 5bn of marketcap,

BFL today has the largest repository of metallurgical knowledge in the region and offers

complete service supply capability to its geographically dispersed marquee

Customers from concept to testing and validation. It has global footprints and a more than

10,000 strong global workforce driving its diverse business activities.

BHARAT FORGE LTD. PRODUCTS

BFL today is among the few global automotive component manufacturers with capability to

offer front line design & engineering, dual shore manufacturing and full service supply

capability.

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Crankshaft, Camshaft, Front Axle Beam and Steering Knuckle.

VARIOUS CUSTOMERS

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VARIOUS DEPARTMENTS IN BFL.

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PRODUCTION DIVISION

1. FORGE MODERNIZATION DIVISION (FMD-I)

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BFL MUNDHWA

PRODUCTION DIVISION

MACHINED COMPONENT

DIVISION(1&2)

A2 LINE

HEAT TREATMENT

DIVISION

FORGE MODERNIZATION DIVISION 1,2,&3

(FMD-1,2,&3)

HEAVY FORGE DIVISION 1&2

(HFD-1,2)

FORGE SHOP

DESIGNING AND QUALITY CONTROL

METALLURGICAL QUALITY

CONTROL(MQC)

CLOSED DIE FORGING

DIVISION(CDFD)

CARPORATE OFFICE

DEPARTMENT

PRODUCTION AND

PLANNING DEPARTMENT

SALES DEPARTMENT

INTERNATIONAL TRADE

DIVISION(ITD)

MATERIALS

FINANCE

DEPARTMENT

OTHER DEPARTMENTS

ENVIRON-MENT

ENGG./CIVIL ENGG.

MACHINE TOOL

BUILDING

SAFETY DEPARTMENT

Forge modernization division is a fully modernized forging plant where the working is

automated. FMD-I produces connecting rods, crankshafts, gear pins.

Details:

There are 5 heavy presses based on its capacity as,

1. 16000 tonnes

2. 12500 tonnes

3. 8000 tonnes

4. 2500 tonnes

5. 2500 tonnes

Stroke length of press is 205 mm and the cycle time is 15 sec.

If the temperature of the billet is either below 1200 degree C or above 1250 degree C

it is rejected.

Per day production of division is 3000 in number.

This line is fully automized.

2. FORGE MODERNIZATION DIVISION (FMD-II)

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In FMD-II all the processes are done by human efforts and by help of hydraulic or pneumatic

systems. In FMD-II there are 4 total lines.

The cutting of material is done by a machine called band saw which is manually operated.

The heating of material is done with the help of rotary oil furnace for front axle beam and

induction heating for crankshaft and connecting rod.

Mainly there are 2 types of presses as,

1. Main Press- It carries 3 parts as,

Bender- It converts the billets into initial shape

Blocker- It gives rough shape to the billet

Finisher- It gives final shape as it has to look

2. Trimming Press- It removes flash around the main part by trimming process.

Mainly connecting rod, crankshafts and front axle beam are manufactured. Material used

for production is alloy steel with different grades.

The production of the division is 1200/day.

INDUCTION HEATING

3. FORGE MODERNIZATION DIVISION (FMD-III)

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The main production flow process for the entire department is same for all 3 divisions. The

capacity of furnace is 18 tonnes i.e. 95 jobs per batch of furnace. The de scaling is done with

the help of high pressure water at 250 bars.

Target per day is 1500 Number

Cycle time is 10 sec on koramato

Cycle time is 40 sec on other machines

The temperature of the heated material is measured by pyrometer

In each batch 1 or 2 jobs are inspected for the quality

The machines are operated by PLC named SCADA(Supervisory Control And

Data Acquisition)

The koramato is most automated forging machine

The clearance between upper and lower die is about 5 mm for blocking and it

is 3 mm for finishing process

There are 3 lines based on press capacities as,

1. 12500 Tonnes

2. 8000 Tonnes

3. 2500 Tonnes

FMD I, II, III basically do closed die forging.

PRODUCTION FLOW PROCESS

4. HEAVY FORGE DIVISION-I & II (HFD I & II)

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Material cutting Material heating De scaling

Finishing Blocking Bending Size reduction

Punching Trimming

The heavy forge division is open die forging where big sized and heavy jobs are

manufactured. The forging of various non-automotive parts like shafts, bar ring,

bushes, discs etc. is carried out. HFD I is equipped with 16000 tonnes hydraulic press

whereas, HFD II is equipped with 4000 tonnes hydraulic press. For handling a job a

separate clamping device, Z-DAS manipulator is provided.

In HFD II shafts for the wind energy & power generation sector, well heads & X-mas

tree parts for the oil and gas industry and pinion shafts & gear blanks etc. for the capital

goods sector are some of the parts that will be manufactured.

Process:

Cutting Heating Hammering

In HFD I there are 5 furnaces to heat the material.

Soaking is done according to weight and grade of raw material.

Furnace capacity is 40 tonnes.

Furnace is oil and SKO fired.

In HFD II there are 2 furnaces having capacity of 120 tonnes.

Each of the furnaces is 10 m long.

The material is soaked for 24 hours.

The target for this department is based on the weight of the material and its soaking

time.

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5. A2 LINE

The processing division of Bharat Forge comprises of all post heat treatment operations like

shot blasting, straightening, magnetic particle inspection, coining, finishing, shot penning and

painting or rust preventing applications.

Shot blasting process:

Steel balls of 0.5 to 1 mm dia. are bombarded on jobs at a speed of 70 m/s to remove scale

form on job.

Straightening:

Job is straightened for closed tolerances.

Magnetic Particle Inspection(MPI 1 &2 )

Magnetic particle inspection can detect both production discontinuities (seams, laps,

grinding cracks and quenching cracks) and in-service damage (fatigue and overload cracks).

Basic steps involved:

1. Component pre-cleaning

2. Introduction of magnetic field

3. Application of magnetic media

4. Interpretation of magnetic particle indications

Finely milled iron particles coated with a dye pigment are applied to the test specimen. These

particles are attracted to leakage fields and will cluster to form an indication directly over the

discontinuity. This indication can be visually detected under proper lighting conditions.

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Crankshaft with service induced crack Lube Hole

• Can detect both surface and near sub-surface defects.

• Can inspect parts with irregular shapes easily.

• Precleaning of components is not as critical as it is for some other inspection methods.

Most contaminants within a flaw will not hinder flaw detectability.

• Fast method of inspection and indications are visible directly on the specimen surface.

• Considered low cost compared to many other NDT methods.

• Is a very portable inspection method especially when used with battery powered

equipment.

• Inspection of large parts may require use of equipment with special power

requirements.

• Some parts may require removal of coating or plating to achieve desired inspection

sensitivity.

• Limited subsurface discontinuity detection capabilities. Maximum depth sensitivity is

approximately 0.6” (under ideal conditions).

• Post cleaning, and post demagnetization is often necessary.

Alignment between magnetic flux and defect is important

Twisting Removes all twist in the job by holding it and twisting it.

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6. FORGE SHOP

In the forge shop the job is prepared using hammering operation. Big billets of steel are put

under the hammer and are repeatedly hammered.

The furnaces used are box type oil jet furnace where in 60% kerosene and 40% oil

mixture is sprayed.

The jobs are heated to the temperature of about 1280 degree C.

25001, 25002 & 1600T Russian press are installed in the forge shop.

All the processes at the forge shop are carried out by human workers.

80% of the jobs prepared in the shop are exported.

Material forged here are alloy steel titanium steel and aluminums.

Large sized cranks up to 4.5 tones are forged.

Main sector of application is Marines.

Siempelkamp press shop and Eumuco press shop is comes under this shop.

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7. HEAT TREATMENT DIVISIONIn heat treatment division the heat treatment of jobs is carried out to obtain various

mechanical and chemical properties. There are various processes as follows,

1. Hardening 2. Tempering 3. Iso annealing 4.Quenching 5. Normalizing 6. Stress

relieving 7.Annealing

• There are two types of furnaces.

1. Continuous furnace 2. Batch or box type furnace

• Material is heated up to 880 degree C followed by quenching

• The tempering is carried out at 460 to 680 degree C

• The capacity of the continuous type furnace is 10500 MT/ month

• In quenching, quenchants used are oil, polymer, AQRF, water, air

• The soaking time depends on critical diameter

• Soaking time is one hour for one inch case dept

FLOW PROCESS OF HEAT TREATMENT

Raw material

Case carburized (5 Hrs.)

Air cooling

Austenizing (30 Min.)

Shallow Quenching in oil Deep cryogenic treatment

Cryogenic

Treatment

Tempering (5 Hrs.)

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8. MACHINED COMPONENT DIVISION I & II (MCD I&II)

Machining of various components carried out in Machined component division. The basic

operation of this department is to finish the jobs and make them ready for packing. In MCD I

all domestic products are machined while in MCD II the products are exported. Various

operations on crankshafts are,

1. Centering

2. Journal turning

3. Drilling

4. Induction hardening

5. Tempering

6. Shot blasting

7. Pin grinding

8. Tapping

9. Balancing

10. Assembly: collar and gear is assembled to crankshafts by push fit.

In Bharat Forge the state-of-the-art machining facility is largest of its kind & has crankshaft

machining capacity of 650000 units/annum. In addition the facility also has the capacity of

machining 500000 Front axle beams and 750000 Steering knuckles/annum.

In MCD I there are 11 production lines, out of which, 6 lines are non-crankshaft and the

rest being crankshaft lines.

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DESIGNING AND QUALITY CONTROL

1. CLOSED DIE FORGING DIVISION (CDFD)

CAD/CAM/CAE is an important department under F.M.D. The soul purpose of the

department is to prepare die design and handed over to die shop. This method is fastest &

accurate.

There are total 7 departments

1. Estimation

2. 3 team

-small

-medium: design is done according to press capacity

-higher

3. CAD Modeling

The die design is carried out according to customers design data sheets. Software’s used for

CAD modeling are UNIGRAPHICS, PRO-E or CATIA.

4. Simulation

In simulation the die design is analyzed for different stresses that would be coming in real

world. Software’s used are ANSIS, HYPERMESH, ABACUS.

5. CAM

Here the program is created for the machinery to give tool path for performing of

production.

6. Die shop

Design is sent to die shop where dies have been created for manufacturing the product.

7. CAE/Fatigue testing

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2. METALLURGICAL QUALITY CONTROL (MQC)

Inspection and testing of raw material is the soul purpose of metallurgical quality control

department to achieve and maintain desired metallurgical properties of the product.

Departmental key effectiveness is measured by development heat treatment process for the

heat treatment shop and maintaining metallurgical quality of forging to customers quality

standards.

Major activities carried out in the division are,

• To study the feasibilities of customers metallurgical in an inquiry and give relevant

comments regarding acceptance or alternatives.

• To study and give clearance on the job control card draft.

• To maintain and update library of various international/national standards.

• Generate and maintain proper records for all SRR and Mill test certificate received

from steel cutting department.

• To carryout raw material inspection and release raw material for production.

• Maintain die-wise cut material records.

• Periodic calculations of all testing equipment in MQC laboratory.

• Testing of forging after H.T.

• Liaison inspection agencies for testing and inspection of forging.

• Audit checking of forging before dispatch and issue of test certificates.

Following are the major facilities available,

• Spectrometers –at KCSSL for chemical analysis.

• Microscope- for metallography (Nikon and Neophot 32).

• Image analyser- for metallography, to determine martensitic rim, inclusion rating.

• Scanning electron microscope- JOEL Japan make for field failure analysis,

fractography etc.

• Rockwell hardness tester.

• Tensile testing machine and impact testing machine Wiedemann Baldwin, USA.

• Rockwell microficial hardness tester- Wilson makes.

• Equotip hardness tester- PROCEQ, Switzerland.

• Micro hardness tester.

• Millipore checking facility.

• P-3121 case depth testing machine- QNET.

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3. DIE SHOP

Die shop is the division where dies manufactured according to the blue print by CDFD by

means of CNC machinery. Following are the types of dies that are manufactured in the die

shop,

1. Blocker

2. Finisher

3. Trimmer

4. Padding

The blocker and finisher are made in the same die block while the trimming is on the separate

die block.

Maintenance also carried out in die shop.

The material for the die used is H-10, H-11. Co-ordinate measuring machine, FARO

arm and linear measuring machine are the means for dimensional inspection.

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CORPORATE OFFICE DEPARTMENTS

1. PRODUCTION AND PLANNING CONTROL (PPC)

The production planning control department co-ordinates with all the internal department of

BFL and plans the production cycle to meet the customer requirements. PPC department in

broader spectrum control the 3 steps i.e. input, processing and output.

The customer demand drives all the processes for meeting the customer demand a proper

balance of what to use, when and how is important.

The PPC department looks over:-

Deciding the production cycle

Process sequence

Roots to complete the job

Shipment

PPC department also does the inventory control with the aim of maximum customer

satisfaction.

It also strives to minimise the discrepancy between the plant job and physically

prepared job.

Other system that falls under this department and its working strategies include material

resource planning: planning of quantity of particular job and insuring a particular amount of

that job is being completed at a prescribed time. The continuous production output is

monitored and maintained on a regular basis.

2. SALES

All the customers demand from the domestic market and the SAARC countries are first made

to the sales. Accordingly the sales department runs the order and the delivery cycle.

Meanwhile it also decides the payments to be made and communicates with customers. The

sales department looks after the domestic market. Thus the sales department is one of the

most important departments at BFL.

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3. INTERNATIONAL TRADE DIVISION (ITD)

As its name implies this department is related to sales and marketing of products of BFL in

the international market. The major customers of BFL are Cummins, Caterpillar, Ford, Dana

group, Dangler, GM etc. the international sales accounts for 50% of total sales from Bharat

Forge.

This department provides all kind of documentation and logistics ranging from making

invoice, packaging, arrangement, contacting with supplying lines etc.

4. MATERIALS

It is the general responsibility of material department to look after all the needs of the

company and then purchase those goods accordingly.

1. General purchase: Materials department look after the general purchases done from local

suppliers from day to day activities.

2. Supplies from outside: All the supplies which are imported from countries abroad are

looked after the materials department. Majority of OEM (Original Equipment Material) is

imported.

3. Steel purchasing: BFL purchases the ram materials from various steel mills. Some of them

are Kalyani carpenters, Kalyani hospets, Adhunik steels, Musco etc. 75 to 80% of materials

are purchased from Kalyani carpenters ltd.

4. Storage: Materials department also has the responsibility of storing the materials

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5. FINANCE

There are 9 sections of finance department,

1. Cash and Bank section – Takes daily bank transaction and the transaction done via cash.

2. Expense – This section looks after the expenses of the company.

3. Salary – Processing of payrolls and other expenses.

4. Payable section – Looks after the payable to the suppliers.

5. Receivable section – Looks after the receiving the money from the domestic and

international customers.

6. Costing and inventory – It looks after the costing.

7. Fixed asset – It keeps the track of the value of the fixed asset owned or to be owned by the

company.

8. General leisure – It co-ordinates between different sections of finance department.

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OTHER DEPARTMENTS

1. ENVIRONMENTAL ENGG. OR CIVIL DEPARTMENT The study and waste management in the BFL is carried out by this department ensuring

minimum damage to the environment. It also aims at reusing waste material so as to ensure

the unused material is not wasted.

Waste is divided into sub categories such as solid hard waste, hazardous waste,

Biodegradable, non-biodegradable and liquid hazardous waste. The management is carried

out by following ways,

Waste water management, Acid treatment plant, Solid waste management

2. MACHINE TOOL BUILDING The machine tool building (MTB) department builds all kinds of machines that are

needed in the company. This department is responsible for

Reconditioning Rebuilding Reprobating

of new machines. Generally the machines are imported and they are reconditioned according

to BFL’s requirement. The necessary software’s provided by FANUC or Siemens. For the

designing purpose Auto-cad and Solid Edge are used by the engineers.

3. SAFETY DEPARTMENT This department works for the safety of the workers and creates awareness about the needs

to obey the norms. They generate awareness in the minds of workers about safety by

providing banners, posters in the shops, relating how to avoid accidents. Every section which

helps people working in that department to work safely.

Each department has one safety officer who is given green helmet. At the same time the

safety department officers are frequently on the safety inspection on the shop floor. There are

some of the works a safety department person does with the company departments. Plant

Safety Inspection, Safety Training, Safety Audit, Risk Assessment.

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SUMMERY

Through this training program we learnt various manufacturing processes and all over

production planning and control. In Bharat Forge we studied about various metallurgical

knowledge, heat treatment, awareness about new product technology and development. We

have got exposure about international sales and marketing strategies. One of the most

important part in the industry is safety and environment. With all this facilities, Bharat Forge

is leading forging industry. Bharat Forge manufactures a wide range of safety and critical

components for the automotive & industrial sector and is a leading manufacturer of power

train & chassis component with market leadership in all major markets.

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