Submitted by

SAURABH BERNAWAL

Mechanical engineering

Krishna institute of engineering & technology

Ghaziabad.

Sage Metals Ltd was established in 1983.

It has its registered office in Delhi, India.

The major products manufactured and exported

by the company are electrical hardware, general

and industrial castings, sanitary & plumbing,

automotive and irrigation applications.

It has facilities for high pressure die casting of

aluminium and zinc alloys, sand casting of

copper alloys, conventional & CNC machining in

high volumes, Investment casting (lost wax

process) of stainless steel (grades 304/316) and

steel stampings and tubular components.

Die casting

Machining

Maintenance & development

Assembly & packing

Stores

Quality control

Tool room

Die maintenance

Die is an example of permanent mould

casting.

Molten metal is forced into the die cavity

(pressure ranging from .7 mpa to 700 mpa)

Types

Hot chamber die casting process

Cold chamber die casting process

Hot chamber processThis process involves the use of a piston which

squeezes the molten metal into the die

cavity through a gooseneck and nozzle.

Pressure ranges from 15 mpa to 35 mpa

The metal is held into the die cavity untill the

metal solidifies into the die.

Cycle time usually ranges from 200 to 300

shots per hr.

Low melting point alloys e.g. Zink, magnesium

tin & lead can be cast with this process.

Cold chamber processMolten metal is poured into the injection

cylinder(shot chamber)

Shot chamber is not heated hence the name

is cold chamber process

The metal is forced into the die

cavity(pressure ranging from 20mpa to 70

mpa)

Machining is the process of removing unwanted

metal from a work piece in the form of chips.

As tool makes contact with

the metal it exerts

pressure on

it resulting in the compression

near tool tip.

This induces shear type

deformation within the metal and it starts moving

upwards along the top face of the tool.

Various types of machining operations are

carried out on casted product

Commonly employed machining operations in

sage metals ltd. Are

Trimming

Drilling

Boring

Tapping

Reaming

Chamfering

Grinding

Turning

Facing

Fettling etc.

To carry out these various machining processes

both general purpose and special purpose

machines are used.

Apart from these there are large number of

cnc lathe and milling machines are also use

to carry out various machining operations at

higher rate of production

EDM is a manufacturing process whereby a

desired shape is obtained using electrical

discharges (sparks).

Material is removed from the workpiece by a

series of rapidly recurring current discharges

between two electrode, separated by

a dielectric liquid and subject to an electric

voltage.

This company uses EDM to manufacture die

for die casting machine.

Vertical Machining Centre (VMC) is a fully

automatic machine which run on by

prgromming set it in.

It is used to produce very complex designed

product.

The programme is set in VMC according to

the design of the final product after this VMC

machined this workpiece according to the

shape required.

Sage metal use this machine to produce the

tool for the EDM.

It is a type of mass finishing manufacturing process used to deburr, radius, descale, burnish, clean, and brighten a large number of relatively small work pieces.

Specially shaped pellets of media and the work pieces are placed into the tub of a vibratory tumbler. The tub of the vibratory tumbler and all of its contents are then vibrated. The vibratory action causes the media to rub against the work pieces which yield the desired result. Depending on the application this can be either a dry or wet process.

In paint shop the machined work is painted according to the requirement.

The work to be painted is first rubbed against emery paper to generate rough surface and then it is subjected to a powder spray by a spray gun.

The product is then kept at high temperature at about 200-250 deg. For about thirty minutes.

Plating is a surface covering in which

a metal is deposited on a conductive surface.

Tin plating is an electrode deposit process

that offers excellent solderability, improves

corrosion resistance, prevents galling of

metal surfaces, and has a low contact-

resistance surface. Tin plating is recongized

for its softness and ductility during the

stamping process. As tin is relatively low in

cost, it is quite commonly used.

The main function of maintenance

department is to maintain and repair factory

equipment and other industrial

machinery, such as conveying

systems, production machinery, and

packaging equipment.

Main objective of the maintenance is to have

increased availability of production

systems, with increased safety and optimized

cost

Maintenance of installed equipment and

facilities

Installations of new equipment and facilities

Inspection and lubrication of existing

equipment

monitoring of faults and failures using

appropriate techniques

Modifications of already installed equipment

and facilities

Keeping records

In assembly shop the different parts of a

product are assembled together

Assembly shop is using

various special purpose

automatic machines,

used to assemble different

parts together.

In packing section the assembled products

are packed.

The products are packed in different

packets provided by

the customers containing

the specification of

the product, labeling etc.

Quality control is the control of quality

during manufacturing.

This company uses the concept of total

quality management.

It perfoms sampling inspection after every

stage of production.

Performing the quality control operation in

production system make the product

realiable and provide satisfaction to users.