VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI – 590018

ARKA Educational & Cultural Trust (Regd.)

JAIN INSTITUTE OF TECHNOLOGY
(A Unit of Jain Group of Institutions, Bengaluru)
Davanagere-577003, KARNATAKA

DEPARTMENT OF MECHANICAL ENGINEERING

FINAL YEAR B.E. (2024 – 2025)

A REPORT

On

“INDUSTRY INTERNSHIP [21INT82]”

UNDER THE GUIDANCE OF

Dr. RAJANEESH N MARIGOUDAR B.E., MTech., Ph.D.

Professor and Head

Dept. of ME, JIT, Davangere

Submitted by

BALAJI E V (4JD21ME001)
 VISVESVARAYA TECHNOLOGICAL UNIVERSITY
BELAGAVI – 590018

ARKA Educational and Cultural Trust®

JAIN INSTITUTE OF TECHNOLOGY
(A Unit of Jain Group of Institutions, Bengaluru)
DAVANGERE–577003, KARNATAKA

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that Report on work entitled “INDUSTRY INTERNSHIP[21INT82]” carried
out by Mr. BALAJI E V (4JD21ME001) is a Bonafide student of Bachelor of Engineering
in Mechanical Engineering of the Visvesvaraya Technological University, Belagavi during
the year 2024- 2025.
It is certified that all corrections/suggestions indicated for internal assessment have been
in corporate in the report deposited in the departmental library. The internship report has been
approved as it satisfies the academic requirements in respect of internship prescribed for the
Bachelor of Engineering degree.

Dr. Rajaneesh N Marigoudar B.E., MTech., Ph.D. Mr. Veeresh Kumar K S

Guide and Head Co-Ordinator,
Dept. of ME, JIT, DVG Dept. of ME, JIT, DVG

Dr. Ganesh D B
Principal
JIT, DVG

EXTERNAL VIVA

Name of the Examiner Signature with date

1.
2.
 ACKNOWLEDGEMENTS

It is my absolute pleasure to present this hard worked Internship to one and all. It has been a
journey of knowledge propelled with shear enthusiasm. The successful completion of any
task would be incomplete without the mention of the team who have constantly guided and
inspired us for the completion of this internship.

I express my gratitude to Mr. Hemanth, HOD for the Connecting Rod Shop Floor,
Sansera Engineering Limited for his valuable guidance, continual encouragement, and
assistance throughout our internship. I greatly appreciate the freedom and collegial respect
he provided. I am grateful for his insightful discussions on technical matters and his
suggestions regarding internship.

I extend my sense of gratitude to my Guide Dr. Rajaneesh N Marigoudar, Head of the

Department, of Mechanical Engineering, JIT, Davanagere for extending support and
cooperation which helped me in completion of internship.

I extend my sense of gratitude to Mr. Veeresh Kumar K S, Assistant Professor, project

coordinators, Department of Mechanical Engineering, JIT, Davanagere for extending support
and cooperation which helped us in completion of the internship.

I extend my sense of gratitude to Dr. Ganesh D B, Principal, JIT Davanagere for providing
congenial atmosphere for completion of internship.

I would also like to thank all our friends and family members for providing support and
motivation to understand this internship.
Mr. BALAJI E V
4JD21ME001

I
 ABSTRACT

This report presents the insights and technical knowledge gained during my internship at
Sansera Engineering Limited, a leading manufacturer of precision components for the
automotive and aerospace industries. The primary objective of this internship was to observe
and understand the complete manufacturing process of connecting rods, a critical engine
component used in two-wheelers and other internal combustion engines.
During the internship, I was exposed to various stages of production, including raw material
selection, forging, heat treatment, CNC machining, surface finishing, quality inspection, and
assembly. The integration of advanced manufacturing techniques such as CNC turning
centres, automated inspection systems, and precision gauging tools was observed throughout
the workflow. Emphasis was placed on quality control, dimensional accuracy, and adherence
to industry standards to ensure optimal engine performance and durability.
The internship provided valuable hands-on exposure to modern manufacturing practices, lean
production strategies, and the importance of process optimization. It also offered a deeper
understanding of how high-strength materials and precision engineering contribute to the
performance and reliability of connecting rods.
This experience has significantly enhanced my technical knowledge, problem-solving ability,
and appreciation for industrial-scale component manufacturing in the automotive sector.

II
 CONTENTS

Sl. No. Content Page No.

01 Acknowledgements I

02 Abstract II

Chapter 01 About the Company 1

1.1 Company Profile 1

1.2 About the Company 1

1.3 Vision 1

1.4 Mission 1
Chapter 02 Company History 2-5

2.1 History of Sansera 2

2.2 Company Customers 3

2.3 Awards and Recognitions 3-5

Chapter 03 Products Manufactured by Company 6-12

3.1 Two-Wheeler parts 6-8

3.2 Four-Wheeler Parts 9-11

3.3 Commercial Vehicle Parts 11-12

Chapter 04 Introduction to Connecting Rods 13-15

4.1 Introduction 13

4.2 Types of Connecting Rods 14

4.3 Materials used 15

4.4 Functions 15
Chapter 05 Manufacturing process of Connecting Rod 16-21

Chapter 06 Weekly Activities Performed 22-29

6.1 Week 01 22

6.2 Week02 22-23

6.3 Week 03 23

6.4 Week 04 24

6.5 Week 05 24-25

6.6 Week 06 25

6.7 Week 07 26

6.8 Week 08 26-27

6.9 Week 09 27-28

6.10 Week 10 28-29

Chapter 07 Conclusion 30
 LIST OF FIGURES

Sl no Figure name Page no.

2.1 Global Presence of Sansera 2

3.1.1 Connecting Rod Types 6

3.1.2 Rocker Arm Types 6

3.1.3 Finger Followers 7

3.1.4 Transmission Parts 7

3.1.5 Steering/Suspension Parts 8

3.1.6 Assembly Components 8

3.1.7 Aluminium parts 8

3.2.1 Four-Wheeler Engine Parts 9

3.2.2 Four-Wheeler Transmission Parts 9

3.3.3 Four-Wheeler Steering/Suspension Parts 10

3.2.4 Trans Axle Parts 10

3.2.5 Generator Shafts 11

3.3.1 Engine Parts 11

3.3.2 Braking System parts 11

3.3.3 Transmission parts 12

3.3.4 Chassis Parts 12

4.3 Forged Steel Connecting rods 15
Week 01 Images
6.1 22
Week 02 Images
6.2 23
Week 03 Images
6.3 23
Week 04 Images
6.4 24
Week 05 Images
6.5 25
Week 06 Images
6.6 25
Week 07 Images
6.7 26
Week 08 Images
6.8 27
Week 09 Images
6.9 28
Week 10 Images
6.10 29
INDUSTRIAL INTERNSHIP

CHAPTER 01

ABOUT THE COMPANY

1.1 COMPANY PROFILE
Name: Sansera Engineering Limited

Address: No. 261/C, Hosur Rd, Bommasandra Industrial Area, Bengaluru,

Bommasandra, Karnataka 560099

Contact No: 8027833056

Email: info@sansera.in
Based in: Bengaluru

1.2 ABOUT THE COMPANY

The company manufactures precision engine components, such as rocker arms, crankshafts,
gear-shifter forks, and connecting rods, for two- and four-wheelers.

Sansera Engineering Limited, is an unlisted public company incorporated on 15 December,

1981. It is classified as a public limited company and is located in Bangalore, Karnataka. It's
authorized share capital is INR 30.50 cr and the total paid-up capital is INR 12.34 cr.

Sansera Engineering Limited's operating revenue range is Over INR 500 cr for the financial
year ending on 31 March, 2023. It's EBITDA has increased by 15.41% over the previous
year. At the same time, it's book net worth has increased by 14.38%.

1.3 VISION
” World Class Engineering Corporation that maximizes stake holders’ value”

1.4 MISSION
“Building an employee driven and socially responsible global engineering corporation
using innovative methods and efficient management for lasting customer loyalty “

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CHAPTER 02

COMPANY HISTORY

2.1 HISTORY OF SANSERA

Sansera was incorporated in 1981 in Bengaluru and commenced commercial production of

passenger vehicle components in 1986. We grew our precision components manufacturing
business organically in India by commencing supplies to the two-wheeler vertical in 1996, for
off road vehicles in 2009, and to the light commercial vehicle vertical in 2011. We set up a
manufacturing facility dedicated to high precision aluminium and titanium machined
aerospace components in 2013. In April 2017, we acquired a 100% stake in Sansera Sweden,
which has facilitated our entry into the heavy commercial vehicle vertical in the automotive
sector, expanded our customer base and improved geographical access to OEMs outside
India.

Fig: 2.1 Global Presence of Sansera

2.1.1 Origin of name Sansera

“SANSERA” was named by the CMD. Mr. Sekhar Vasan. It is the combination
of three Mr. Vasan family members
 Mr. Siva Subrahmanya VaSAN – Father of CMD
 Mr. SEhkar Vasan – CMD
 Mrs. RAdha Vasan- Mother of CMD

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2.2 Company Customers

The Company has large base of customers.

Domestic Customers:

Two Wheelers Four Wheelers

1. BAJAJ 1. MARUTI SUZUKI
2. HONDA 2. HONDA
3. SUZUKI 3. VOLKSWAGEN
4. ROYAL ENFIELD 4. FIAT
5. KAWASAKI 5. TOYOTA
6. KTM
7. HERO

Overseas Customers:
Two Wheelers Four Wheelers
1. TRIUMPH 1. FCA (Fiat Chrysler Automobiles)
2. YAMAHA 2. CNH Industrial
3. HONDA 3. JCB
4. KTM 4. DAIMLER
5. POLARIS

2.3 Awards and Recognitions

1. 2001- Awarded the Best Machining award by Yamaha Motors Private Limited
2. 2004- Awarded the Supplier award for quality from Honda Motorcycles and Scooters
India Private Limited
3. 2005- Awarded the Vendor Performance award by Maruti Suzuki India Limited
4. 2007- Awarded the Samman Patra Award by the Ministry of Finance, Department of
Revenue, Government of India
5. 2008- Received ISO 14001:2004 certification for Plant 2 and Plant 3 by TUV NORD
CERT GmbH

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6. 2009- Awarded the Grand Award for QCDDM by Honda Motorcycles and Scooters
India Private Limited
7. 2010- Received ISO 14001:2004 certification for Plant 4 and Plant 6 by TUV NORD
CERT GmbH
8. 2011- Awarded the Quality and Service Award by Ducati Motor Holding Spa, Italy
Received a certificate of recognition as a Star Export House by the Ministry of
Commerce and Industry, Government of India.
Received ISO 14001:2004 certification for Plant 7 by TUV NORD CERT GmbH.
Received BS OHSAS 18001:2007 certification for Plant 7 by TUV NORD CERT
GmbH.
9. 2012- Received ISO 14001:2004 certification for Plant 5 by TUV NORD CERT
GmbH
10. 2013- Awarded the Perfect Quality Award by Fiat
Received ISO/TS 16949:2009 certification for Plant 5 by TUV NORD CERT GmbH.
Awarded the Silver Award for part development by India Yamaha Motors Private
Limited.
Awarded the Quality Excellence Award from General Motors Company.
11. 2014- Awarded the Best Collaboration Award by Ducati Motor Holding Spa, Italy
Received ISO/TS 16949:2009 certification for Plant 4 by TUV NORD CERT GmbH.
Awarded the Quality Excellence Award by General Motors Company.
Awarded a “3-star rating” by Confederation of Indian Industry – EHS.
12. 2015- Awarded the Quality Excellence Award by General Motors Company
Awarded the Competitiveness Award by General Motors Company.
13. 2017- Awarded the Quality Performance Award by Volkswagen AG
14. 2018- Awarded the Quality Award Gold from Bajaj Auto Limited for Plant-1, Plant-2
& Plant-7
Awarded the Quality Excellence Award from India Yamaha Motors.
Awarded Supplier Quality Award from KTM Austria.
15. 2019- Awarded the FCA EMEA from Fiat- 2019.
Awarded the Zero-Defect Supply Award from Toyota Kirloskar Motor.
Awarded the TPM Excellence Award from JIPM – for Plant 6.
16. 2020- Awarded the Silver Boeing Performance Excellence Award for 2019 from the
Boeing Company.

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17. 2021- Awarded for achieving target in the category of QUALITY from TOYOTA
KIRLOSKAR MOTORS PVT LTD in 2021.
Awarded for achieving target in the category of DELIVERY from TOYOTA
KIRLOSKAR AUTO PARTS PVT. LTD in 2021.
Awarded for achieving target in the category of QUALITY from TOYOTA
KIRLOSKAR AUTO PARTS PVT. LTD in 2021.
Awarded for achieving outstanding contribution in the category of Zero-Defect
Supplies from TOYOTA KIRLOSKAR AUTO PARTS PVT. LTD in 2021.
Awarded for achieving outstanding contribution in the category of Zero-Defect
Supplies from TOYOTA KIRLOSKAR MOTORS PVT. LTD in 2021.
Awarded for achieving target in the category of DELIVERY from TOYOTA
INDUSTRIES ENGINE INDIA PRIVATE LIMITED for the FY 2021-22.
18. 2022- Awarded the LACP VISION AWARDS – GOLD AWARD FOR ANNUAL
REPORT 2021-22
Awarded the BAJAJ AUTO – QUALITY “PLATINUM” AWARD
Awarded the BEST CSR IMPACT INITIATIVE – MANUFACTURE INDUSTRY
Awarded the GLOBAL CSR – BEST USE OF CSR PRACTICES
Awarded the ET ASCENT- COMPANY OF THE YEAR (AUTOMOTIVE)
Awarded the TOYOTA INDUSTRIES ENGINE INDIA – BEST SUCCESS STORY
AWARD FOR “MY PRODUCT MY RESPONSIBILITY”
Awarded the QUALITY MONTH CELEBRATION
Awarded the QUALITY MONTH AWARD, NOVEMBER 2022
Awarded the GOLDEN PEACOCK AWARD 2023 FOR TRAINING

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CHAPTER 03

Products Manufactured by Company

3.1 Two-Wheeler Parts

3.1.1 Engine Parts

1. Connecting Rods
 Fractured
 Integral
 Split

Fig:3.1.1 Connecting Rod Types

2. Rocker Arms
 Roller Rocker Arm
 Sintered Tip Rocker Arm
 Chrome Plated Rocker Arm

Fig:3.1.2 Rocker Arm Types

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3. Finger Followers

Fig:3.1.3 Finger Followers

3.1.2 Transmission parts

1. Balancer Shaft
2. Gear Shift Fork

Fig: 3.1.4 Transmission Parts

3.1.3 Steering / Suspension Parts

1. Stem Comp Part

2. Stem Comp
3. Arm relay

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Fig: 3.1.5 Steering / Suspension parts

3.1.4 Assembly Components

1. Crankshaft Assembly
2. Gear Shift Fork
b

Fig: 3.1.6 Assembly Components

3.1.5 Aluminium parts

1. Step Holders-Rider
2. Step Foot Holder

Fig: 3.1.7 Aluminium parts

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3.2 Four- Wheeler Parts

3.2.1 Engine Parts

1. Connecting Rods
2. Sprockets
3. Rocker Arms
4. Adapter
5. Rocker Shaft

Fig: 3.2.1 Four-Wheeler Engine Parts

3.2.2 Transmission Parts

1. Gear Shift Fork

2. Housing Shift Lever Shaft
3. Housing Shift Lever
4. Arm Shift
5. Shaft Propeller
6. Spacer Input Gear
7. Shaft Control

Fig: 3.2.2 Four-Wheeler Transmission Parts

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3.2.3 Steering / Suspension Parts

1. Attachment Lower Ball Joint (LH & RH)

2. Input Shafts

Fig: 3.2.3 Four-Wheeler Steering/ Suspension Parts

3.2.4 Trans Axle Parts

1. Pinion Differential Drives (Low)

2. Gear Motor Counter Drives

Fig: 3.2.4 Trans Axle Parts

3.2.5 Generator Shafts

1. Motor generator Shafts

2. Motor Rotor Generator Shafts

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Fig:3.2.5 Generator Shafts

3.3 Commercial Vehicles Parts

3.3.1 Engine Parts

1. Connecting Rods
2. Valve Bridges
3. Bracket
4. Support Injector
5. Rocker Arm

Fig: 3.3.1 Engine Parts

3.3.2 Braking System Parts

1. Crank Shaft for Braking Assembly

2. Guide Bush

Fig: 3.3.2 Braking System Parts

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3.3.3 Transmission Parts

1. Gear Shift Fork

2. Intermediate Ring

Fig: 3.3.3 Transmission Parts

3.3.4 Chassis Parts

1. Cabin Tilt System Parts

g

Fig: 3.3.4 Chassis Parts

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CHAPTER 04

Introduction to Connecting Rod

4.1 Introduction

A connecting rod (or conrod) is a mechanical component in an internal combustion engine

that connects the piston to the crankshaft. It transmits the reciprocating motion of the piston
into the rotational motion of the crankshaft, enabling the engine to deliver mechanical power.

The connecting rod is one of the most critical components in an internal combustion engine,
serving as a vital mechanical link between the piston and the crankshaft. It plays a central
role in converting the reciprocating (linear) motion of the piston into rotational motion at the
crankshaft, which ultimately drives the vehicle’s wheels. Without the connecting rod, the
powerful energy generated during the combustion process inside the cylinder would not be
transferred efficiently to produce useful mechanical work.

Connecting rods are subjected to extreme stresses due to high combustion pressures, rapid
movement, and fluctuating tensile and compressive loads. Therefore, they must be designed
for high strength, fatigue resistance, durability, and precise dimensional tolerance.

In the context of automobile engines, particularly two-wheelers and four-wheelers,

connecting rods are usually forged to enhance their mechanical properties. The
manufacturing process involves multiple machining and inspection stages to ensure that the
component performs reliably over millions of cycles.

In high-performance applications such as racing, aerospace, and marine engines, the choice
of materials and design variations of connecting rods (like H-beam or titanium rods) become
even more critical.

This component may appear simple in shape, but it is highly engineered, with its design
directly affecting engine performance, fuel efficiency, durability, and vibration
characteristics.

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4.2 Types of Connecting Rods

1. Integral Connecting Rod
An integral connecting rod is manufactured as a single solid piece without any
separation at the big end.
Key Features:
 The big end and small end are part of the same solid component.
 No cap; not detachable at the crankshaft end.
 Usually used in low-stress applications or in small engines.
Applications:
Small gasoline engines, model engines, and some early-generation engines.
2. Split-Type Connecting Rod
A split connecting rod is manufactured in two pieces: the rod and a cap. The big
end is split horizontally, allowing the crankshaft journal to be enclosed.
Key Features:
 Two parts: the main rod and the big end cap.
 Held together by high-strength bolts.
 Most common type used in internal combustion engines.
Applications:
Used widely in cars, motorcycles, trucks, and industrial engines.
3. Fractured (Cracked) Connecting Rod
A fractured or cracked connecting rod is initially made as a single piece and then
intentionally broken at the big end using a controlled fracture process to form a
natural and irregular mating surface.
Key Features:
 Provides a perfect interlocking fit when reassembled.
 The mating surfaces are unique and non-replicable.
 Bolted together after fracture for precise alignment.
 Applications:
Modern automotive engines, especially in mass production (used by companies like
BMW, Volkswagen, Toyota etc.).

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4.3 Materials used

Connecting rods are typically made of:
 Forged steel (common in performance or heavy-duty engines)
 Aluminium alloys (lighter, used in high-speed engines)
 Titanium (for racing or aerospace applications)
 Powder metallurgy (in some modern mass production)
Sansera Engineering, for instance, uses forged steel due to its high strength and
fatigue resistance.

Fig:4.3 Forged Steel Connecting Rods

4.4 Functions
1. Motion Conversion: Converts the piston’s up-and-down movement into the
crankshaft’s rotational motion.
2. Load Transfer: Transfers combustion force from the piston to the crankshaft.
3. Bearing Support: Houses bearings at both ends (small end and big end) to support
rotation and reduce friction.
4. Mechanical Linkage: Maintains the geometric relation between piston and crankshaft.
5. Damping Vibrations: Helps in minimizing engine vibrations during combustion.

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CHAPTER 05

Manufacturing Process of Connecting Rod

Sansera Engineering Limited employs a comprehensive and technologically advanced

process for manufacturing connecting rods, ensuring high precision and quality. Below is an
expanded and detailed breakdown of each step involved in their manufacturing process:

1. Forging of Connecting Rod

While the term "casting" is sometimes used, Sansera primarily utilizes forging to
manufacture connecting rods. Forging enhances the mechanical strength and fatigue
resistance of the rods. The process involves:

 Fullering: Distributing material to prepare for shaping.

 Blocking: Preliminary shaping of the rod.
 Finishing: Final shaping to achieve desired dimensions.
These steps are often integrated into a single die block to optimize efficiency.
2. Big End Boring, Small End Drilling, Chamfering of B/E one side
 Big End Boring: This process involves enlarging the pre-drilled hole at the big end
of the connecting rod to precise dimensions, ensuring a perfect fit with the crankshaft
journal.
 Chamfering of One Side: Chamfering removes sharp edges from the bore,
facilitating easier assembly and reducing stress concentrations.
 Small End Drilling: A hole is drilled at the small end to accommodate the piston
pin, maintaining strict alignment and dimensional accuracy.

Machine Parameters

 Machine Used- Makino Slim 3 PC VMC-232

 Machine Weight- 4.95 tonnes
 Power supply- 30KVA, 200V, 50Hz
 MOBIL Velocite oil No 3- Capacity-28 Liters
 Castrol Hyspin AWS 32- Capacity-6.5 Liters
 Lubricant- KLUBER L801

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 Coolant used- Castrol Hysol, Capacity-300 Liters

3. Heat Treatment of Connecting Rod

The connecting rod undergoes heat treatment to enhance its mechanical properties. This
process involves heating the rod to a specific temperature and then cooling it at a controlled
rate to achieve the desired hardness and strength. Heat treatment also relieves internal stresses
induced during forging and machining.

There are several processes includes in Heat treatment of connecting rod. They are,
 Fixture Loading
 Pre- Washing
 Pre-Heating
 Case Hardening/ Carbonising/ Hardening
 Post Washing
 Sub Zero Treatment
 Tempering
 Metallurgical Inspection
4. Big End Chamfering (Other Side)

Chamfering the opposite side of the big end ensures uniformity and prepares the rod for
subsequent machining and assembly processes.

Machine Parameters

 Machine Name- SHM 208

 Total Power Capacity- 11.9KVA
 Volts- 415V
 Current- 16.6A
 Chamfer Tool- Ф22-Ф33×HSK A50 SCM T09T3
 Speed- 1000-1500rpm
 Feed- 200-300 mm\min

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5. Chamfering of Small End

Bevelling the edges of the small end hole to remove sharp edges, aiding in assembly and
reducing potential stress risers.

6. Face grinding

This step involves grinding the sides of the connecting rod to achieve the specified thickness.
Precision grinding ensures uniformity, which is critical for maintaining balance and proper
engine function.

Machine Parameters

 Machine Used- DDG 222

 Power supply- 30KVA, 200V, 50Hz

7. Oil Hole Drilling

Drilling precise oil passages to ensure adequate lubrication between the connecting rod and
other engine components, crucial for reducing wear and extending service life.

Machine Parameters

 Machine used- SID 204

 Air Pressure production- 4-5bar
 Coolant Concentration- 3%-4%
 Tool- Chamfer drill Ф4.10×90º×sФ8(50×5.6)CARB
 Speed-2400-2800rpm
 Feed- 120-150mm/min
 Machine Cycle time- 6sec

8. Big End Boring

Machining the big end bore to exact dimensions to house the crankshaft journal, ensuring
proper fit and function.

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Machine Parameters

 Machine Used- SFB-206

 Total Power Capacity- 27KVA
 Volts-415V
 Current- 37.5A
 Phase-3Ph
 Fixture used- P260453
 Tool- Boring Tool Ф32.94 (1200-1400rpm)
 Feed- 100-120 mm/min
9. Small End Boring

Precision machining of the small end bore to accommodate the piston pin, maintaining tight
tolerances for optimal performance.

Machine Parameters

 Machine Used- SFB-206

 Total Power Capacity- 27KVA
 Volts-415V
 Current- 37.5A
 Phase-3Ph
 Tool- Boring Tool Ф13.95 SH16 (1200-1400rpm)
 Feed- 120-140 mm/min
10. Big End Honing

Using honing machines to achieve a fine surface finish and precise diameter in the big end
bore, enhancing bearing performance and longevity.

Machine Parameters

 Machine Used- SVH-215

 Fixture- P450949
 Tool Holder- Collect Chuck Tc40/ER 40×080
 Tool- Honing ST/GAIT L55×H13.9×W6-B107H3.5Ф35

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 Speed- 500-600rpm
 Feed- 10000-12000 mm/min
11. Small End Honing

Similar to the big end, honing the small end bore ensures a smooth surface and accurate
dimensions for the piston pin interface.

Machine Parameters

 Machine Used- SVH-228

 Speed- 500-600rpm
 Feed- 10000-12000 mm/min

This is the last procedure in the production of connecting rod. After this step the parts will
move to further cleaning and then bend, twist inspection and correction and then final
quality checking

12. Cleaning

Thorough cleaning to remove any debris, oils, or residues from the manufacturing process,
preparing the rod for inspection and assembly.

13. Bend and Angular Twist Correction

Employing specialized equipment to detect and correct any bending or twisting in the rod,
ensuring alignment and balance for engine operation.

14. Quality Checking

Implementing advanced inspection techniques, including vision systems and robotic

inspection, to verify dimensions, surface finish, and overall quality, ensuring each rod meets
stringent standards. Quality inspection of connecting rods ensures durability, performance
and safety in engines.

1. Visual Inspection
 Checks for surface defects, cracks and machining irregularities
 Ensure proper finishing and cleanliness

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2. Dimensional Inspection
 Uses Vernier Caliper, Micrometre, Air plug gauges to verify critical dimensions
 Ensures correct bore diameter, length and alignment
15. Packing

Carefully packaging the finished connecting rods to protect them during transportation and
storage, maintaining their integrity until final assembly.

CHAPTER 06
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Weekly Activities Performed

6.1 Week 01

 During the first week of my internship, I observed the entire process involved in the
manufacturing of connecting rods which are used in Honda, Royal Enfield, TVS,
Bajaj.
 Understanding complex manufacturing processes, Interpreting technical drawings and
tolerances safety and workplace. Took detailed notes, asked questions to supervisor
and operator, and referred to technical manuals and workflow.
 Gained an understanding of the complete connecting rod manufacturing process,
including machining, heat treatment Improved proficiency in reading technical
drawings, understanding tolerances, following industrial protocols and documenting
key observations.

Fig:6.1 Week 01 Images

6.2 Week 02

 Observed and learned about CNC machines used in the production of connecting
rods. Understood the machining process for brands like Bajaj, TVS, Royal Enfield,
and Honda. Studied the different stages of manufacturing and quality control.
 Understanding complex CNC programming. Managing work under industrial safety
regulations.

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 Observed machine operators and studied CNC codes. Followed safety guidelines and
received guidance from mentors

Fig: 5.2 Week 02 Images

6.3 Week 03

 Studied the heat treatment process used for different automotive parts. Collected
detailed information about the heat treatment process from the in-charge. Observed
various stages of heat treatment, including heating, quenching, and tempering.
 Understood the importance of heat treatment in improving the mechanical properties
of components.
 Identifying the effects of different temperature ranges on material properties.
Understanding the technical aspects of different heat treatment methods

Fig: 6.3 Week 03 Images

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6.4 Week 04

 Attended training sessions on “Campus to Corporate” focused on preparing for

corporate life. Participated in interactive modules and discussions.
 Successfully completed all training modules. Understood key aspects of corporate
culture and workplace expectations.
 Gained insights into leadership qualities, effective communication, relationship-
building, professionalism, and work ethics.
 The session was insightful and helped bridge the gap between Campus and corporate
expectations. It boosted confidence for future roles.

Fig:6.4 Week 04 Images

6.5 Week 05
 Observed the quality checking process of connecting rods. Learned about the steps
followed in quality checking. Understood the packing process for connecting rods.
 Gained insights into quality control measures. Observed real-time implementation
of quality standards in manufacturing. Understood how defective parts are
identified and handled.

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Fig: 6.5 Week 05 Images

6.6 Week 06
 Participated in the Inter-Plant Skill Olympiad at the company. Assisted in organizing
and executing the event where participants demonstrated their skills in CNC
programming, machining, quality analysis, and CMM. Acted as a coordinator for the
CNC category, ensuring smooth operations and participant management.
 Gained exposure to different CNC programming and machining techniques. Improved
event coordination skills while managing participants and overseeing the CNC-related
tasks. Contributed to the overall success of the event by assisting in its execution.
 The Inter-Plant Skill Olympiad was a valuable learning experience. Coordinating the
CNC category allowed me to develop leadership, communication, and technical skills.
Seeing participants from different plants showcase their expertise was inspiring, and I
gained deeper insights into CNC machining and quality analysis.

Fig: 6.6 Week 06 Images

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6.7 Week 07
 Observed the production process of connecting rods, including different types and
their respective manufacturing stages.
 Gained in-depth exposure to the machining, forging, and inspection phases of
connecting rod production; started documenting the differences in design and
materials.
 This week deepened my understanding of core mechanical components and gave me
real-time exposure to industrial practices, improving both technical knowledge and
observation skills.

Fig:6.7 Week 07 Images

6.8 Week 08

 Explored the design, function, and manufacturing process of connecting rods used in
engines. Attended sessions and discussions focused on the types of materials used and
the factors affecting performance and durability.
 Gained detailed knowledge about connecting rod components, including their
mechanical role in internal combustion engines. Understood the significance of
material selection and how it influences strength, weight, and efficiency.
 This week was informative and engaging as I got to dive deep into a core mechanical
component — the connecting rod Understanding its functions and materials gave me a
broader view of engine mechanics and the importance of material science in design
and performance.

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Fig:6.8 Week 08 images

6.9 Week 09
 Observed the manufacturing process of connecting rods using CNC machines.
Monitored the machining parameters, tooling setups, and quality inspection methods.
Assisted in routine maintenance checks and documentation of production data.
 Gained a complete understanding of each stage in the CNC machining process for
connecting rods, including roughing, semi-finishing, and finishing operations. Started
preparing a report on the efficiency of different CNC programs used.
 This week deepened my understanding of core mechanical components and gave me
real-time exposure to industrial practices, improving both technical knowledge and
observation skills.

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Fig: Week 09 Images

6.10 Week 10
 Continued observing the manufacturing process of connecting rods, including forging,
machining, and quality inspection. Attended discussions with supervisors to
understand technical specifications.
 Gained deeper insights into each stage of the connecting rod production process and
documented standard procedures followed on the shop floor.
 Improved understanding of forging techniques, CNC machining operations, and
quality control parameters. Enhanced observation and technical documentation skills.
 This week deepened my appreciation for precision in mechanical manufacturing.
Observing experienced technicians highlighted the importance of accuracy and
consistency in mass production.

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Fig: 6.10 Week 10 Images

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CHAPTER 07

CONCLUSION
The internship at Sansera Engineering Limited provided a comprehensive exposure to the
industrial manufacturing environment, particularly in the production of connecting rods—an
essential component in internal combustion engines. Over the course of the internship, I
gained hands-on knowledge of various production processes including forging, CNC
machining, heat treatment, surface finishing, and quality inspection.

Through continuous observation and interaction with experienced engineers and technicians,
I developed a strong understanding of precision manufacturing, the importance of tolerances,
material properties, and the application of quality standards. The company's emphasis on
automation, lean manufacturing, and strict quality control taught me the significance of
efficiency and consistency in mass production.

This experience has not only enhanced my technical skills but also improved my problem-
solving ability, teamwork, and attention to detail. Overall, the internship has been a valuable
stepping stone in bridging the gap between academic concepts and real-world industrial
practices in mechanical engineering.

In addition to technical learning, I also gained insight into industrial work culture, safety
protocols, and teamwork. The mentoring and support from engineers and supervisors helped
me connect theoretical knowledge from my academic studies to its real-world applications.
Their willingness to explain complex procedures and share practical tips created a strong
learning environment.

This internship has significantly boosted my confidence in pursuing a career in mechanical

and manufacturing engineering. It has also inspired me to further explore areas like materials
science, automation, and product design. Overall, my time at Sansera Engineering Limited
has been a transformative experience that has laid a solid foundation for my future
professional journey.

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