Industrial Internship Presentation

TrellebrogVibracoustic (India) Private Limited, Mohali.

Submitted By:Pankaj Dogra

Introduction

Training is defined as the systematic development of the knowledge, skills and attitudes required by an individual to perform a given task or job successfully. Training aims at improving the organization’s performance through the enhanced performance of the employees. The major purposes of training are preparing an individual to work as per the corporate world updating skills, managerial succession and satisfying personal growth needs.

Objectives

• To develop the qualities required for a manager and provide an excellent learning opportunity.• To understand the import and export Market with due Focus on Marketing strategies.• To compare products and range of products produced by TrelleborgVibracoustic with other

NVH producers.• The SIP provides the students to know the actual working situation and understand the

corporate culture.• To make understand how to undertake assignments/job along with the day-today functions of

the company.• To provide a platform to take up On-the–job training and develop a network which will be

useful in enhancing career prospects.

Company Profile

TrelleborgVibracoustic is the global market leader in the field of automotive vibration control technology. TrellebrogVibracoustic manufacture automobile products such as bearings, mounts, springs, isolators, and mass dampers reduce the noise and vibrations caused not only by power trains, but also by adverse road conditions. In this industry, rubber is main raw material which is further used for insulating the parts. This process is done, so that unwanted vibration & noise can b minimized in an auto mobile vehicle.

Active Vibration Control Detecting and Neutralizing Disruptive Vibrations

Downsizing and cylinder deactivation help to reduce fuel consumption and CO2emissions. Nevertheless, engines with fewer cylinders generate more vibrations, as the time intervals between the ignitions are longer. Activating and deactivating cylinders also produces vibrations. Because conventional dampers work passively, they are not always able to eliminate these types of disturbances. Active Vibration Control (AVC) from TrelleborgVibracoustic detects and tackles these types of vibrations on an individual and specific basis.

Work Area

We believe that the key to successful production while maintaining high quality lies in the design and concentration of the faculty. TBVC is built with high bias infrastructure across all NVH product manufacturing facilities.

Customer Base:

At Vibracoustic total customer satisfaction is our primary concern and we value strong customer relationship. We are committed to anticipating, understanding and meeting our customer’s needs and expectations.

Various Departments

• Security Wing• Personnel Department• Incoming Inspection• Material store• Finance Department• Time office• Lab (Quality)• Quality Assurance

Product Range

Vibrations in the automobile are excited by the engine and the road. Understanding and mastering vibration control requires sound know-how about the application areas drive train, power train, chassis and suspension.

Products Manufacturing

Power train: • Engine mount• Hydro mount• Gearbox

mount• Torque strut• Transmission

Mount

Products Manufacturing

Chassis• Control arm bush• Shackle bush• Body mount• Leaf spring bush• Tie rod bush

Products Manufacturing

Drive train• Drive shaft damper• Propeller shaft damper

Products Manufacturing

Suspension• Air bellows• Jounce bumper

Process Flow Chart

Safety First

Project Undertaken

Identification of moulding defects

Various Defects in Injection Moulding• Short Rubber• Deep Injection Point• Air Blisters• Rubber Crack • Loose Bond • Dirty Mold• Metal Defects• Metal Damage• Old Rubber• Primer Failure

SHORT RUBBER

Possible Reasons: • Mould is not closed.• Usage of old rubber.• Incorrect positioning of injection nozzle on the

mould.• Improper clamping/injection pressure.• Possible blockage in injection hole.• Usage of under/over size metal.• Unbalanced rubber volume/ Viscosity/ scorch

High.• Low mould temperature

Effects of This Failure:

• Undesirable stiffness of the part.• Inferior aesthetic appearance.• Occurrence of noise and vibrations in the

car.• Failure due to loss of function.• Dissatisfaction of the customer

DEEP INJECTION POINT

Possible Reasons: • High/low top mould temperature.• Excessive dwell pressure.• Excessive dwell time.• Improper design of Gating system.

Effects of This Failure:

• Results in weak area.• Development of cracks in the part.• Early malfunction of the part

AIR BLISTER/ BUMPING

Possible Reasons:• Improper bumping stroke/time.• Dirty mould.• High mould temperature.• Vacuum not functioning.• Metal treatment problem.• Rubber viscosity too Low.• Moisture in rubber compound

Effects of This Failure:

• Loss of function during application.• Early breakdown of part.

RUBBER CRACKS

Possible Reasons:• Excessive flash due to high rubber volume.• Use of unfit metal parts.• Possible cavity damage.• Excessive mould opening speed.• Excessive application of mould release agent.• Operator fault during mould re-opening.• Rubber compound too fast

Effects of This Failure:

• Enlargement of crack during application may result in part failure.

• Undesirable stiffness of the part.• Failure due to loss of function.• Occurrence of noise and vibrations in

the car.

BONDING FAILURE

Possible Reasons:• Mould Temperature too high/low.• Bonding agent too old/new.• Too Thin/ Too thick bonding agent film

on the metal.• Usage of unclean mould.• Low injection speed/ pressure.

Effects of This Failure:

• Failure due to loss of function.• Occurrence of noise and vibrations in

the car.• Discomfort to the driver.

DIRTY MOULD

Possible Reasons:• Improper mould cleaning.• Carelessness of new operator.• Less temperature in the mould .• Improper spray of the release agent.• Improper mould cleaning.

Effects of This Failure:

• Poor aesthetic appearance.• Dirty mould at functional area may

result in part failure.• Results in customer dissatisfaction

METAL DEFECTS

Possible Reasons:• Supplier fault.

Effects of This Failure:

• Poor aesthetic appearance.• Customer dissatisfaction.• Area of porosity might become weak

and can lead to failure of part.• Metal defect at functional area can

lead to fitment problem (0 Km failure).

METAL DAMAGE

Possible Reasons:• Use of unfit metal.• Damage of the cavity.• Incorrect placement of metal.• Excessive mould opening speed.• Mould setting problem.• Assembly tool problem.• Excessive mould/ injection pressure

Effects of This Failure:

• Poor aesthetic appearance.• Customer dissatisfaction.• Area of porosity might become weak

and can lead to failure of part.• Metal damage at functional area can

lead to fitment problem (0 Km failure).

OLD RUBBER/ CURED RUBBER

Possible Reasons:• Incorrect injection unit temperature.• Flash in the cavity.• Leakage of rubber at nozzle/plunger

Effects of This Failure:

• No bonding between old and good quality.

• Might come off during application.• Might result in failure of part.• Occurrence of noise and vibrations in

the car

FLOWMARKS

Possible Reasons:• Injection speed too fast/slow.• Usage of old rubber.• Bonding agent too fresh/thick.• Temperature from injection aggregate

too high/low.• High/low mould temperature.

Effects of This Failure:

• Heavy flow marks lead to rubber crack during application.

• Heavy flow marks indicate improper joining of rubber layers.

• Heavy flow marks affect stiffness and hence, performance of the part.

• Light flow marks lead to poor aesthetic appearance as they are on the surface only.

Learning’sIt improved my skill to interpret the process engineering drawings

and gives me the experience, to convert the design into product.This activity polish me, how to work in a team to meet the

production target following all quality norms. Excellent opportunity was given by Plant Management by giving

the practical shape to my innovative ideas.This training gives me the learning that customer satisfaction is

prime motive in any industry; it can be achieved only by providing the product (value for money) at right time and right place with minimum cost.

Last but not least, the importance of Safety measures in working environment and personal life.

References:

• www.tbvc.Com• Supervisor• Shift In-Charge• Daily Diary• Operators• Single & Multi-cavity development Head• H.O.D of Plant-I and Metal Treatment Plant

Thank Youo Keep Learning & Keep Growing

Pankaj DograBranch: Mechanical