A

Summer Training Report

taken under
Caparo Maruti Lmt. Gurgaon.


Submitted by : Submitted to :
Sumant Soni
Roll No.-11EJ1ME110
ME (7
th
Sem.)
Contents
Caparo Group
Caparo History
Caparo Companies
Gurgaons Manufacturing Plant
Caparo Products
Product Info




Caparo Group
Caparo is more than a successful business enterprise - it is a
story of people, of values and human effort.
- Lord Paul, Chairmen and Founder.

Caparo Vehicle Products (CVP) is a grouping of innovative well
established Tier 1 and 2 component design, engineering and
manufacturing companies providing advanced solutions to the
automotive, motor sport, commercial and niche vehicle markets
as well as other sectors. Offering design, rapid prototyping and
sample development, as well as series production and line side
delivery, the division is able to provide full vertical integration as
well as component solutions to its customers.


HISTORY
Customers
Gurgaons Manufacturing Plant
Operational since - Feb. 1996
Total area - 12,100 Sq.m.
Build up area - 5,600 Sq.m.
Capacity - 2.4 mn line stroke p.a.
Investment - INR 100 cr
Man power employed - 330 employees
PRODUCTS
Outer Body Panel
Large Inner Panel
Reinforcement
Brackets
Cross Members and Chasis Parts
General Stampings
Stampings
Metal Stamping manufacturing is the process of creating
metal parts by applying extreme pressure to a blank piece
of metal and forming the metal into a desired shape. The
stamping machine includes a specially made form or die
which gives the stamped part shape.
Machines used in stamped manufacturing range from a
simple hand press or Hydraulic Press, to the much larger
machines referred to as Drop Hammers. All stamping
machines incorporate a form or die to give the stamped
metal the desired shape.
The operations associated with stamping are
blanking, piercing, forming, and drawing


Equipments
The equipments of stamping can be categorized to two
types:
1. Mechanical Presses
2. Hydraulic Presses

Mechanical Presses: Mechanical presses has a
mechanical flywheel to store the energy, transfer it to
the punch and to the workpiece. They range in size
from 20 tons up to 6000 tons. Strokes range from 5 to
500 mm. and speeds from 20 to 1500 strokes per
minute.
Mechanical Press
Sheet Metal Stamping
Stamping presses and stamping dies are tools used to
produce high volume sheet metal parts. These parts
achieve their shape through the effects of the die
tooling.
Production stamping is generally performed on
materials .020 to .080 thick, but the process also can
be applied to foils as thin as .001 or to plate stock with
thickness' approaching 1.000
Formability is the primary attribute of sheet metal
material. Formability is further defined as the materials
ability to be:
1. Bending
2. Stretching
3. Drawing
The metallurgical term for these qualities is ductility.
Ductility is the materials ability to deform and elongate
without fracture. The extent to which a stamping is
subjected to such deformation is directly related to the
parts overall shape and geometry. Other factors also
influence the materials formability. They include:

1. The die design
2. The press
3. The press speed
4. Lubrication
5. Sheet metal feeding mechanisms
6. Monitoring and control systems
The stamping manufacturing process in very capable of
high production runs. Depending on the complexity of the
part, and additional manufacturing steps ( progressive
stamping ) required for the final part, will drive the effective
cost-per-part of stamping manufacturing. Typical stamping
speeds do vary, however many high production stamping
manufacturers are capable of 30 to 80 stamping stokes
per minute. The main process followed in stamping
production are as :

1. Blanking
2. Drawing
3. Forming
4. Machining
5. Piercing
Blanking
Blanking is cutting up a large sheet of stock into smaller
pieces suitable for the next operation in stamping, such
as drawing and forming. Often this is combined with
piercing.

Drawing
In drawing, a blank piece of sheet metal is restrained at
the edges, and the middle section is forced by a punch
into a die to stretch the metal into a cup shaped drawn
part. This drawn part can be circular, rectangular or just
about any cross-section.
Forming
Forming is similar to bending. Complex parts such as U-
sections, channel sections of different profiles can be
produced by doing multiple bends.

There is no change in thickness. Good dimensional
repeatability as well as close tolerances is possible with
this process.
Forming
Piercing
Piercing is the operation of cutting internal features (holes or slots) in
stock. Piercing can also be combined with other operations such as
lance and form (to make a small feature such as tab), pierce and
extrude (to make an extruded hole). All these operations can be
combined with blanking.

Piercing of all the holes is best done together to ensure good hole-to-
hole tolerance and part repeatability. However if the material distorts,
the method described below can be done.

When there are large numbers of holes, in a tight pitch, there could be
distortions, due to the high amount of tension on the upper surface due
to stretching and compression on the bottom surface. This causes the
material not to lay flat. This can be avoided/lessened by staggering the
piercing of the holes. Holes are punched in a staggered pattern; then
the other holes are punched in the alternate staggered pattern.
Piercing
Thank You !!!