SUMMER INTERNSHIP AT

ACEY ENGINEERING PVT

LTD

AN INTERNSHIP REPORT

Submitted by

KUSHWAHA NILESH LAXMISINGH

200280102054

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

in
Automobile Engineering
L D College Engineering, Ahmedabad.

Gujarat Technological University, Ahmedabad

July,2023
 L D College of Engineering, Ahmedabad
Navrangpura, Ahmedabad (Affiliated with GTU)

CERTIFICATE

This is to certify that the project report submitted along with the project titled
ACEY Engineering Pvt Ltd has been carried out by Kushwaha Nilesh Laxmisingh
under my guidance in partial fulfillment for the degree of Bachelor of
Engineering in
Automobile 7th Semester of Gujarat Technological University, Ahmedabad during
the academic year2023-24
Prof. Vivek G Trivedi Prof. R J Jani

Internal Guide Head of the Department

 L D College of Engineering, Ahmedabad
Navrangpura, Ahmedabad (Affiliated with GTU)

DECLARATION

We hereby declare that the Internship report submitted along with the Internship
entitled ACEY Engineering Pvt Ltd submitted in partial fulfillment for the
degree of Bachelor of Engineering in Automobile to Gujarat Technological
University, Ahmedabad, is a bonofide record of original project work carried out
bymeat ACEY Engineering Pvt Ltd. Under the supervision of Prof. Vivek Trivedi
and that no part of this report has been directly copied from any student’s reports
or taken from any other source, without providing due reference.

Name of the Student

Sign of Student
Kushwaha Nilesh Laxmisingh
 ACKNOWLEDGEMENT

I am really happy for having such a chance to be an internship at a huge

industrial set up name ACEY ENGINEERING Pvt. Ltd. I like to express my
sincerness to my external guide Mr. kiran M. Variya continuously guiding me
in any difficulty, give me their best knowledge of work I really thankful to
my internal guide also who give me this opportunity of internship and I also
really thankfulto our head of the department PROF. R J JANI Sir.

I am really thankful to my parents and friends who help me during

my internship,which supports me to complete my work.

I also thankful all the engineers and all the workers of company who
help us during ourrequirements.
 ABSTRACT

This two weeks internship is very useful for me as a student of Automobile engineering, due
to this training I understand the procedure of manufacturing in the industry and also got how to
perform the operation practically.
this report shows that which types of cable produce in the company and it analysis and
explores efficiency of production with respect to quality and productivity.
My main goal was to study the equipment and process used in the
industry, product line, machinaries involved in manufacturing process.
During this training I got the brief knowledge about machine like wire stranding machine,
bunching machine, flattening machine, auto spring coilling machines, extruder machines etc.
 INDEX

Chapter 1: Overview of the Company

1.1 History of company
1.2 Different Product

Chapter 2: Overview of Different department

2.1 Work carried out in each department
2.1.1 SPRING DEPARTMENT
-Flattening process
-Auto winding machine
-spring coiling process
2.1.2 OUTER DEPARTMENT
-extrusion machine
-Outer coating
-Sleeves
-Liner
2.1.3 STRANDING DEPARTMENT
-Core winding
-Rewinding
-Wire stranding machine
2.1.4 ASSEMBLY DEPARTMENT
-Inner line
-Light and heavy line
-Dipstick line

Summary
 CHAPTER 1 : OVERVIEW OF THE
COMPANY

1.1 HISTORY OF COMPANY

Established in the1980, ACEY Engineering Pvt. Ltd. Has successfully

made a mark as one of India’s leading manufacturer and supplier of
Control Cables to major Original Equipment Manufacturers (OEM’s)
in the automobile industry. They have also cater to other non-
automotive sectors like Earth Moving
Equipment, Railways, Marine, Electrical ,Agriculture etc. Started as
a machine shop by visionary leader ,Acey began manufacturing
Control Cable since 1982.
From there on ,it has been agrowth story, year on year, primarily because they have
considered quality and technological innovation as their top most priority. They are one
of the only cable manufacturing India to have all cable manufacturing facilities like
outer making, machine shop, inner manufacturing, plastic moulding, casting etc. in-
house. The last four decades have been a journey in the pursuit of excellences they can
deliver what is committed to their clients, on time, all the time.

ACEY is the single largest source of the control cables to Bajaj Auto Ltd for their three
and Tata motors for their commercial vehicles. With a solid base in Billimora, South
Gujarat, We have expanded Acey’s Portfolio to deliver products and services
globally, with a installed capacity of 25 to 30 millions cables per annum.
1.2 DIFFERENT PRODUCT

o Auto motive Products

- Clutch Cables
- Throttle Cables
- Accelerator Cables
- Gear Cables
- Starter cables
- Choke Cables
- Speedo meter Cables
- Bonnet Opener Cables
- Dipstick Assembly
- Engine Stop Cables
- Parking Brake Cable
- Seat Lock Cable

Clutch Cable Throttle Cable Accelerator Cable Gear Cable

Starter Cable Choke Cable Speedometer Cable Bonnet Opener Cable

Dipstick Assembly Engine Stop Cable Parking Brake Cable Seat Lock Cable

Fig1.1AutomotiveProducts
 o Non-Automotive Products

- Hand operated accelerator cables (Tractors)

- Foot operated accelerated cables (Tractors)
- Wire rope arrangement for breaking system (Railways)
- Throttle cables (Marine)
- Gear select assy with cable (Earth Moving Equipment)
- HVAC cable

Hand Operated Accelerator Foot Operated Accelerator Wire Rope Arrangement For
Cables (Tractors) Cables (Tractors) Braking System (Railways)

Throttle Cable Gear Select Assy

(Marine) With Cable (Earth HVAC Cables
Moving Equipment)

Fig1.2Non-AutomotiveProducts
 CHAPTER 2 : OVERVIEW OF DIFFERENT
DEPARTMENT
Acey consist of four department they are Spring Department, Outer Department,Stranding
Department and Assembly Department. Below fig gives an idea regarding organised
layout of the departments until final product is manufacture.
Spri

Coated Spring, Sleeves, Coated

Li

Inner send for assembly

Inner Wire

Fig2.1 Over view of Different Department

2.1 WORK CARRIED OUT IN EACH DEPARTMENT

2.1.1 Spring Department

In Spring Department, Spring is manufactured from raw materials like Stainless Steel and
Galvanized Steel. Spring is a helical winding or a sheaf of steel. Spring manufactured in
this department prevent inner wire from damaging due to external forces or banding and
also allow frictionless ease movement of inner wire.

 Processes carried out in spring department are as follow,

1. Flattening Process
2. Auto-Winding Process
3. Spring coiling Process

 Different diameter of raw material wire with their colour code

- Diameter1.2mm–Black Colour
- Diameter1.6mm–Blue Colour
- Diameter1.8mm–Yellow Colour
- Diameter2.0mm–Orange Colour
Flattening Process
In this process the raw material i.e. RQ wire is flattened into required thickness flatten wire
by using Flattening Machine. First of all, raw material is loaded in a machine. Then
initially this raw material is manually pulled through a set of rollers and manually rotated
two to three turn of the spool. The gap between the rollers is adjust by screw and nut
according to thickness of flatten wire required. This gap is measured with dial gauge. Then
after machine is turned on and which goes on flattening the wire and winding it on spool.
Flattening machine is shown in Fig 2.1. The main components of Flattening Machine are
AC drive, a set of roller, Gear box, Limit switch, etc.

Fig2.2FlatteningMachine
Operation process

- Adjusting the gap of the first roller.

- Turn on the machine's power supply switch on.
- TurnonthecoolantflowforgalvanizedwireandcoolantnozzlePlacethejetas needed at the
end of the wire guide.
- Used end cut from guide, wire, guide, and, flattening roller Turn on the
machine switch after receiving.
- Check the thickness of the wire in micro metre according to the quality plan.
- If the non-conferencing goes, reset the gap between the rollers and get the
required precaution.
- Check the used thickens and check the peat colour, check the range according
to the visual aid. Remove the non-confirmed flatted wire during setup.
- If the flat wire surface is ruff, then guide the flatting area Replace on top of roller.
- If crack sappeara round the flatuse Reporting to Supervisor.
- If going to flatted wire correctly, then the receiver bobbin Apply and lock.Wrap
a few bobbin wires and turn off the machine.

Maintenance Process

- Clean the machine and check the oil indicator.

- Check the coolant of the applicable machine.
- If the quantity seem stobe less than the required quantity, prepare the coolant
and drop it to the required level.
- Remove zinc powder or dust from pay off. And repair or replace the bearing if necessary.
- Adjust the tension on the sleep clutch if needed.
- Change the flattening area of the roller every month to remove the
non- conformance of the flanged wire.

 ThicknessofflattenwirevariesaccordingtosizesofrawwiresusedasshowninTable2.1

Table2.1Differentthicknessofflattenwire

Sr.no Wire Size Flatting

Thickness
1 1.2±0.03 0.60±0.03
2 1.6±0.04 0.80±0.05
3 1.8±0.04 0.98±0.03
4 2.2±0.05 1.20+0.04/-0.02
Auto Winding Machine

In this process spring or sheaf of steel is produced by winding flatten wire on liner. Spring
prevent inner wire from damaging and also allow inner wire to move with ease. The
machine use to manufacture is auto winding machine. Auto winding machine is a modified
lathe machine in which chuck consist of set of three guiding rollers and carbide die tool at
the centre. Initially spool of flatten wire is loaded at tail stock of auto winding machine.
And liner on which flatten wire is to be winded is fed through the head stock. Then flatten
wire is manually fed through the guiding roller and then through the carbide forming die.
Then the chuck is rotated for two to three turns of spring. The spring starts for mingon
liner & coming out of die. Now Start the Machine by pressing the Switch. The Machine
start coiling of spring which shall come out on the Right hand side of machine through the
tail stock continuously. Auto winding Machine is shown in figure Fig 2.3.

Fig2.3Auto Winding Machine

Operation Process
- Turnonthemachineswitchandmakeameter-longspring.
- Turn off the machine. Using a micro meter O.D. Measure and id. Measure with
Vernier. - Hold the spring vertically according to the quality plan and check its
strength.
- Looks like spring surface waves, overlapping (one on top of the other) And when
the gap appears, resume tooling.
- Cut off the exposed end of the spring, then turn on the machine Pass the spring
through the guide tube.
- When the end of the spring reaches the limit switch, the machine automatically shuts
off. Then cut the rest of the spring with a spring guide, attach the spring to the joint
piece and place it in the drum.

Maintenances Process
- Send tools for maintenance as per the tool maintenance schedule or when non-
conference takes place asper the filing for mat of the tooling work order. As you get
the tools, update the tool history card.
- Dusting or cleaning zinc powder or torso.
- Clean the head stock with an air jet or duster.
- Check the free rotation of the coiling pin and replace it if it deserves to be replaced.

 Diameter of Spring varies according to sizes of flat wire thickness used

as shown in Table 2.2

Table2.2Differentdiametersofspring

Sr No. Flat wire thickness Liner Spring O.D.

I.D. O.D.
1 0.60±0.03(1.2mm) 2.5 3.0 4.0+0.15/-0.05mm

2 0.60±0.03(1.2mm) 2.7 3.4 4.4+0.05/-0.05mm

3 0.60±0.03(1.2mm) 3.2 4.0 5.0+0.15/-0.05mm

4 0.80±0.05(1.6mm) 2.7 3.4 4.9+0.10/-0.05mm

5 0.98±0.03(1.8mm) 3.5 4.5 6.0+0.20/-0.05mm

6 1.20+0.04/-0.02(2.2mm) 4.2 5.2 7.5+0.15/-0.1mm

7 1.20+0.04/-0.02(2.2mm) 3.5 4.2 6.6+0.15mm

8 1.20+0.04/-0.02(2.2mm) 5.4 6.8 9.0+0.15/-0.1mm

Spring Coiling Process

In this process continuous helical spring is coiled on Spring coiling machine. In this type
of machine there are four tools used to make a spring. This spring are more flexible in
comparison to the auto-winding spring. Long pipes are used to contain this spring as they
have high flexibility and cannot be kept in a basket. Helical spring can be made from this
type of machine. Spring coiling machine is shown in the Fig 2.4 below.

Operation Process

- Turn on the switch of the machine, make the spring approximately 100 to 150 mm
according to the manual control.
- Turn off the machine, pull the mandrill and pull the extra flat wire out of the start
end of the sting.
- Pass the mandrel through the collet with the spring, open the collet lock and rotate
the collet spring as required to hold the collet spring tight.
- The pressure is maintained. Turn on the machine and make an approximate one-
meter spring. Check the outside diameter with a micro metre and scale Spring
stiffness on the machine with a scale Check.
- Visually check the overlap and gap of the spring. Set the tension of the guiding
bucket and pay off the bobbin if the gap appears. Check the fee rotation of the
sliding roller if it overlaps.
- If there is a whirlpool or bend in the spring, Reduce the holding pressure to reduce
the whirlpool but be careful not to sleep from spring collect. If the flat coil looks
OK, Pass the spring through the spring guide tube. In the machine when the spring
touches the end of the spring guide tube shut it down.

Maintenances Process

- If the I.D. If it seems low, check the Mendel diameter and change it if
necessary or adjust the bearing pressure to increase the ID.
- Iftheinnerdiameterseemsmoreorless,dowirethicknessandmandrelsizecheck.
- Check the finishing coiling of every bobbin wire in mandrel smoothness. Check
the finishing of the coils of each bobbin wire
2.1.1 Outer Department

ThespringmanufacturediscoatedwithamixtureofPVCandHDPEinExtrusionmachine to
prevent it from damaging due to various factors.
▪ In Outer Department mainly four products are manufactured as shown in Fig 2.4,
Fig 2.5, Fig 2.6, Fig 2.7.
- Coating on spring
- Liner
- Sleeve
- Railway wire coating

Fig2.4 Coating on spring Fig2.5 Liner

Fig2.6 Sleeves Fig2.7 Railway Wire

Extrusion Machine

The extrusion machine is for the manufacture of different products in this department.
Various components of the extrusion machine are heater, Hooper, FRL unit, blower, die,
cooling tank, caterpillar, etc. Extrusion machine forces or pull unformed material into
alignment guides and shaped dies to produce length of stock forms and cross sectional
shape. The extrusion machine is shown in Fig 2.8.

Fig2.8 Extrusion Machine

In extrusion process the mixture of PVC and HDPE is used as a raw material for coating.
Sometimes Moly-graph powder is added to add colour to the products. This mixture is fed
through a Hooper. This mixture is passed through a series of heaters in the extrusion
machine where is gets melted and then passed through Die of desired shape.
Thedesireproductcomingoutofthedieispassedthroughwatertankforcooling.
Then it is passed through printing roller and length measuring roller. It continuously
pulled by caterpillar pulling system.
Raw Materia lUsed

- Poly Vinyl Chloride(PVC)

- High Density Polyethylene(HDPE)
- Moly Graph

 HDPE is mainly used for liner fabrication and inner coating. When moly Graf is used
to colour the liner. Nylon used for railway cable coating. PVC is mainly used for outer
coating i.e., spring coating . Fig2.9,Fig2.10,Fig2.11,showsdifferentrawmaterial
used

Fig2.9 Black Colour PVC Grains Fig2.10 Black Colour Moly Graph

Fig2.11White HDPE Grains

Operation Process

- Turn on the water flow in the barrel jacket and open the water in let coke of the tank.
- Remove PVC flow from vacuum tank, cooling tank, and captain roller.
- Close the top cover of the vacuum tank and turn on the vacuum pump.
- Set the screw speed and caterpillar speed according to the process
validation table and pass the directly extruded liner through the caterpillar.
- O.D. With the help of Vernier and I.D. Check according to the quality plan
from the pin gauge.
- If the inside diameter is not as required, then the vacuum chamber Adjust the vacuum.
- Cut the cross-section of the extruded liner and the inspected extruded liner. If
the extruded liner cross-section is oblong, reduce the pressure of the captain
roller.
- Cuttwolinersoftherequiredlengthasperthequalityplanandgivethemtothe supervisor for
the first piece and last piece approval.

Maintenance Process
- Maintain the policy level in the hopper to avoid an empty extruder.
- Clean the machine using an air jet or duster.
- Check the current drone and replace it if the drone current is zero.

Railway wire

 Thereistotal5temperaturezoneinlinerextrudermachine.
- Zone1–170±20°C
- Zone2–165±20°C
- Zone3–165±20°C
- Zone4–160±20°C
- Zone5-170±20°C
Outer coating

 For black coating:-Takeamixtureof10kgPVCand150gblackmasterbatch

 Thereistotal5temperaturezoneinOuterCoatingextrudermachine.
- Zone1=190°±20°C
- Zone2=200°±20°C
- Zone3=200°±20°C
- Zone4=200°±20°C
- Zone5=290°±20°C

 Table2.3showscoatingondifferentsprings

Table2.3Coatingofspring

Sr. Spring O.D. Coating

No. Diameter
1 4.0+0.15/-0.05mm 5.0
2 4.4+0.05/-0.05mm 5.5
3 4.9+0.10/-0.05mm 6.0
4 5.0+0.15/-0.05mm 6.0
5 6.0+0.20/-0.05mm 7.0
6 6.6+0.15mm 8.0
7 7.5+0.15/-0.1mm 9.0
8 9.0+0.15/-0.1mm 10.5
Sleeves

 For Grey coating:-Takeamixtureof10kgPVCand120gmGreymasterbatch.

 For black coating:-Takeamixtureof10kgPVCand150gblackmasterbatch
 Thereistotal5temperaturezoneinsleeveextrudermachine.
- Zone1=160°±20°C
- Zone2=180°±20°C
- Zone3=180°±20°C
- Zone4=150°±20°C
- Zone5=150°±20°C

 Table2.3showsthedifferentsizeofsleevesmanufactured.

Table2.4TypesofSleeveanditscolour

No. Sleeve Sleeve

diameter(mm) colour
1 5.5*7.0 Black

2 6.5*8.0 Black

3 7.5*9.0 Black

4 1.2*1.4 Black

5 6.5*8.0 Wight

6 6.5*8.0 Grey
Liner

 For Grey coating:-Takeamixtureof10kgPVCand120gmGreymasterbatch

 Thereistotal5temperaturezoneinlinerextrudermachine.
- Zone1=160°±20°C
- Zone2=180°±20°C
- Zone3=180°±20°C
- Zone4=150°±20°C
- Zone5=150°±20°C

 Table2.4showstypeoflinermanufactured.

Table2.5TypesofLinerManufacturedinExtruderMachine

No. Types of Screw speed Caterpillar

liner (RPM) speed(RPM)
1 2.7*3.4 820 800
2 2.5*3.0 750 820

3 1.8*2.5 720 785

4 3.5*4.5 850 330
5 4.2*5.2 900 300
2.1.3 STRANDING DEPARTMENT

 In this department mainly two types of machines are used

1) Bunching machine 2) Stranding machine

 There are mainly two types of materials used to make inner.

- Stainless Steel
- Galvanized Steel
 Stranding Department includes three process.
1. Core Winding
2. Rewinding
3. Wire Stranding

Core Winding process

Core winding process is done to increase strength and load caring capacity of core wire.
Machine used in this process is Core winding Machine shown in Fig 2.6. This machine is
used to combine Stainless steel or Galvanized steel wire into one core wire or central wire.
The core wire is a combination of 7 wire of raw material wires. Core winding process
increases strength of the load carring capacity of core wire. The machine use for core
winding process is known as Bunching machine which shows in below figure.

Fig2.12 Bunching Machine

 Table2.6WireSizeTable

Length of wire for Length of wire for

Wire
size[mm] small bobbin large bobbins
[m] [m]

0.22 2500 --------

0.25 2500 --------

0.30 2500 --------

0.32 2500 5500

0.37 -------- 4500

0.39 1800 4000

0.45 -------- 4000

Rewinding Process

Core wire bobbin from the core winding machine is rewinded into small size bobbins.
Rewinding is done to increase flexibility of core wire and also
help unbending the bend occurs during core winding process. Rewinding of core wire into
small size bobbins is also important so that it can be loaded in stranding machine.
Wire Standing Machine

We saw wire stranding machine in which inner wire is made by 1*6 structure and this
inner is used as core wire in 1 * 6 * 12 and also used as core wire in 7*7. Then we saw
wire stranding machine in which inner wire with 1*6 * 12 structure is prepared. 12
different bobbins are set in the bobbin tube and 1 *6* 12 inner wire can be made using
it. Similarly in bobbin tube 6 different bobbins are set up to create an inner with 7 * 7
structure. Inside 6 bobbins are 1 *6 core wire. This is how a 7* 7wire rope is made from
it.WirestrandingmachineandstrandingprocessisshowninFig2.13&Fig2.14.Table
2.5&Table2.5showsdifferentsizeofwirestranded.

Fig2.13 Wire Stranding Machine

Fig2.14 Wire Stranding Process

 Table2.7 Different Size of Wire Stranded

Center Core Closing Final

wire Core diameter wire size[mm]
Construction diameter
size wire [mm]
[mm] size[mm] [mm]
1*6 0.22 0.22 0.66 --------- ----------
1*6 0.50 0.50 1.50 ---------- ----------
0.17± 0.17±
1*6*12 0.2±0.005 0.54 0.90
0.005 0.005
0.32± 0.32±
1*6*12 0.37±0.015 1.00 1.60
0.015 0.015
0.37± 0.34±
1*6*12 0.39±0.015 1.17 2.00
0.015 0.015

Table2.8 Different Size of Wire Stranded

Construction Core1 Core2 Final size

[mm]
Centre Core Core Centre Core Closing
wire wire Diameter wire Wire wire
size size [mm] size size diameter
[mm] [mm] [mm] [mm] [mm]

7*7 0.17± 0.17 0.51 0.13± 0.13± 0.39 1.20 +0.084/

0.001 ± 0.01 0.01
-0.012
0.01

7*7 0.20± 0.17 0.54 0.17± 0.17± 0.51 1.12 ±0.14

0.01 ± 0.01 0.01
0.01

7*7 0.25± 0.25 0.75 0.22± 0.22± 0.66 2.00 ±0.10

0.01 ± 0.01 0.01
0.01
2.1.4 Assembly Department

Assembly department consist of three lines.

- Inner Line
- Light and Heavy Line
- Dipstick Line
GeneralLayoutofAssemblyDepartmentinFig2.15.

Fig2.15 General Layout of Assembly Department

Inner Line

▪ Cutting Process

- In this section inner wire passes through various process and gets ready for assembly.
- First inner wire from stranding section and it will be cut according to plan.
- Abrasive Cutter Machine is shown inFig2.16.

Fig2.16AbrasiveCuttingMachine

▪ Flaring Process

- Aftercuttingtheinnerwireissendforflaringprocess.Inflaringprocess,theend part of inner

wire is flared.
- Themainfunctiontheflaringprocessistoholdthecastingpartandmouldingpart.
- Fig2.17showstheflaringmachinewhichisworkonpneumaticsystem.

Fig2.17FlaringMachine
  Die Casting

- After flaring process casting is done on Die Casting Machine.

- The main function of pneumatic die casting machine is to make the required
cable end on the inner end.
- Zincisused as the material for casting.
- Different die is used for making different types of cable end.
- Fig2.18 shows the pneumatic die casting machine. And die casting process
is shown in Fig 2.19.

Fig2.18PneumaticDieCasting

Fig2.19DieCastingProcess
  Shaving Process

- Aftercastingprocessisdonetheextramaterialisremovedbyshavingprocess.
- For shaving process manual hand operated shaving and mechanical power
press is used.
- Fig2.20showstheshavingmachine.

Fig Mechanical Power Press for Shaving Process

 Soldering Process

- After shaving process soldering process takes place.

- The main function of soldering process is to apply alayer of zincon the
opposite end part of inner wire.
Light and Heavy Line

Light Line

 First outer cable is collected from outer section, and then it will cut according to
plan in outer cable cutting machine and go for grinding and deburring process.
 The power press machine is used for outer end crimping, in which the cap,
adjuster, rubber etc. are fitted on cable end.
 And next step is to inner cable insert into outer cable, an inner cable is cut
according to required size with the help of hand shear machine or
abrasive cutter machine.
 The inner cable end is casted with the help of vertical diecasting machine and
 Extra material of cable end is removed by using having machine.
 Fig shows mechanical power press machine for assembly.

Fig Mechanical Power Press Machine for Assembly

Heavy Line

 The same process is done in heavy line but only difference is the
heavy cable is manufactured in heavy line.
 Mechanical power press machines are used to assemble different child parts on cable.
 The main component of mechanical power press machine is motor ,
Flywheel, clutch and brake, Drive shaft, Gear box, Die etc.
 When paddle is pushed then two rotating disc is engaged and one rotation
is achieved and force is applied on die.

26
Dipstick Line

 Dipstick is one of the several measurement devices which are used to check the
oil level in vehicle.
 Dipstick line is started at flared inner wire process. The flared inner wire is
coming from flaring process and goes for moulding process.
 For moulding nylon material is used in injection moulding machine.
 Fig shows the injection moulding machine.

Fig Injection Moulding Machine

Operation

 Firsttherawmaterialnylonispreheatedinovenat100°Cfor2hours.
 Themainpurposebehindpreheatingnylonmaterialisbecausenylonmaterialis
 Hard After preheating it will ready for heating in moulding machine.
 Required temperature for different four zones are as follow,
- Zone1=370°±30°Catpressure145bar
- Zone2=250°±30°Catpressure135bar
- Zone3=240°±30°Catpressure50bar
- Zone4=220°±30°Catpressure50bar
 With the help of screw the molten material enters the die.
The molten materialthen takes the shape of the die due to the
cooling water passed into the die.
 After moulding is done then the other end part of dipstick
cutting according toplan and at this part moulding or
casting process is done according to requirement.
 Fig2.23showscastingonendpartofdipstick.

Fig2.23DipstickEndPartCasting

Packaging

 In this section all cables collected from the assembly

section and then it willpack into single packet or multi
packet.
 After it will store into storage area.
 Summary

I successfully completed my 15 Day Internship at ACEY ENGINEERING

PVT.LTD . I trained myself and worked in verious Department of the company
under the supervision of Mr. kiran m variya . I was able to gain hands on experience
of manufecturing of cable and clutch from different type of vehicle like passenger
vehicle in accelerator cable,clutch cable,hood release cable ,gear shifter,in 3
wheeler like clutch cable ,accelerator cable, gear cable, decompression cable,in2
wheeler like throttle cable ,clutch cable,brake cable, in earth moving equipment
like gear select assy with cable. During this training period I was able to
witness,perform and help and learn how to manufacturing cable and clutch through
different process in different department like spring department,outer department
,stranding department and assembly line. I gained a lot of practical knowledge
and experience about the manufecture a different type of clutch for different types
of vehicles during my internship.
 Reference

REFERENCE

 Photos and other description from company website https://www.aceyindia.com/

 Geo Raju, Mohan Lal Sharma, Makkhan Lal Meena Recent methods for optimization
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