SUBMITTED BY — PANKAJ and SUNITA RANI MECHANICAL

SUBMITTED BY: - PANKAJ and SUNITA RANI MECHANICAL ENGG. ROLL NO: -12305 &12326 SEM: - 5 th DRONACHARYA COLLEGE OF ENGG; GURGAON

CERTIFICATE This is to certify that the project entitled “Brake & Fuel Line” submitted by Mr. Pankaj & Miss. Sunita Rani is a bonifide record of work carried out by her under my supervision from 15 th June 2011 to 31 st July 2011. the contents of this thesis, in full or in parts have not been submitted to any other institute or university for the award of any degree. Mr. Mohan Singh. Sr. Executive(HR)

INDEX PROJECT TITTLE ACKNOELEDGEMENT COMPANY INTRODUCTION About TI Automotives World Organization Structure Product Overview Environment & quality INDUSTRY OVERVIEW PROJECT INTRODUCTION Objective Of Training Objective Of Project Introduction To Project ANALYSIS AND FINDINGS CONCLUSION AND RECOMMENDATIONS ANNEXURE

ACKNOLEDGEMENT I am very grateful to all under whom I completed my summer training. I would like to give my heartiest thanks to Mr. Mohan Singh who give me opportunities (letter to join as trainee) to do training at Bundy India Limited. I would like to express my deep gratitude to Mr. Ravi Verma (project guide) at Bundy India Limited for their keen interest, valuable guidance and constant encouragement during the course of my accomplishment of this project. I am very grateful to them for introducing me to the technicalities and explaining the subtleties of the project and process flow of the plant.

COMPANY INTRODUCTION

TI Automotive has maintained the position of a premier supplier to an everchanging global market since 1922, with advances in small diameter steel tube manufacture, design and fabrication Technology and innovation have always been our driving force, offering far more than just tubing expertise to the automotive industry. Bundy double wall tubing is manufactured from a low carbon, tight tolerance continuous strip of copper plated cold rolled steel, double wrapped (through 720 degrees) and brazed in a controlled atmosphere to form a double-walled tube.

COMPANY BACKGROUND INFORMATION TI Automotive is the world's leading supplier of fluid storage, transfer and delivery systems including brake, fuel and air conditioning applications. FOUNDED TI Automotive Ltd was formed as an independent company in 2001 in England. Following the merger of TI Group with Smiths Industries in December 2000, TI Group Automotive Systems became a division within Smiths Group plc. In July 2001, the automotive division demerged from Smiths Group. EMPLOYEES TI Automotive has more than 16, 000 employees in more than 100 facilities worldwide. BUSINESS DIVISIONS TI Automotive is divided into two major divisions. The Fuel Systems group has approximately 40% of company sales and the Fluid Carrying Systems group has 60%. GROWTH CHORONOLGY TI Automotive's roots are in the remarkable transformation of TI Group plc from a declining British company in 1986 to a thriving global business by 2000. TI Group, which originated as Tube Investments Ltd in Birmingham, England in 1919, grew its automotive business with these major acquisitions:

PRODUCT OVERVIEW Our core product offerings focus on the design, development and manufacture of multilayer blow molded plastic fuel tanks with integrated fuel delivery module assemblies, including turbine or gerotor pumps, electronic control modules, sensor units and fill and vapor control valves. Complimenting these leading edge complex fuel tank systems are TI Automotive's rigid and flexible fuel and brake lines, each available with a comprehensive range of coating applications and unique connector technology. Our total systems solutions provide the world's automotive manufacturers with a filler neck fuel rail package that is designed to optimize cost, space, weight and fitment parameters whilst surpassing safety and emissions requirements. Additionally, TI Automotive offers world class air conditioning module assemblies. Steel and aluminum accumulators and unitized receiver dryers are integrated with rigid and flexible hose assemblies to provide efficient and optimum performance in this high temperature environment.

Fluid Carrying Systems Our routing expertise comes into its own in the crowded vehicle underbody. Brake and fuel line bundles, designed to optimize space and maximize fitment speed, save valuable assembly time. Supplied on a “just-in-time” or sequence-delivery basis, we provide simple inventory. Control and reduced assembly-line congestion.

Brake & Fuel Products : TI Automotive provides a brake and fuel solution for each customer application. Our tubular products include rigid brake and fuel lines, flexible fuel lines, and high-pressure diesel products designed to meet a variety of customer needs. Corrugated monoand multi-layer tubes and assemblies complete the portfolio for fuel-vapor systems. A comprehensive range of coatings, which exceed corrosion and abrasion protection standards, enhances product quality and durability

Air Conditioning Tube & Hose Assemblies: Ever-changing emission, fuel efficiency, and cost requirements demand enhancement of current airconditioning systems as well as innovation in alternate refrigerant technology. As a driving force for cost-effective materials, design, and processes for the mobile air conditioning “loop, ” TI Automotive continues to set standards within the industry. Our combination of coupling, bending, and connection technology enables us to meet our customers’ unique needs for quick connectors, in-line heat exchangers, and high-pressure couplings.

Heater & Radiator Hose Systems We offer a wide range of hose constructions and diameters to match our customers’ needs, including high-temperature requirements. Manufacturing capabilities include formed, coupled hoses with tube or quick connectors and pre-positioned clamps (mechanical/adhesive).

Other Automotive Products Our commitment to lean manufacturing has pushed our connector technology to the forefront of the automotive industry, and TI Automotive produces more quick connects than anyone else in the world. From high-pressure quick connects to spin-welding joints between a quick connector and flexible tube line, we provide solutions for every manufacturing need. In addition to meeting the automotive industry’s low-permeation standards, our connectors make for easy installation at the assembly line. TI Automotive also manufactures air bag tubes and other formed tubular products in a variety of intricate shapes to meet our customers’ specifications. These products are supplied to all tiers of the automotive supply cha

Product Quality: Copper Plated Double Wall Steel Tubing specifications SAE J 527, ASTM A 254. Meets automotive brake tube specifications worldwide Available in coils, straight boom lengths, cut-to-length, or fabricated assemblies Available annealed Some common applications include brake lines, high-pressure fuel injection lines, hydraulic line and compressor lines Product Features Product Benefits Double wall construction Designed to withstand high internal pressures and combat vibration fatigue Bead free no weld flash inside or outside the tube Smooth, clean, precise I. D. Copper finish on inside and outside of tubing Facilitates brazing tubing to fittings, stampings and other parts Available in a wide variety of coatings. Extended corrosion protection

Single Wall Low Carbon Steel Tubing Meets or exceeds specifications SAE J 525, SAE J 526, SAE J 356 A, ASTM A 269, and ASTM A 268. Meets all automotive industry standards. Some common applications include: o fuel supply and return lines o vent and vacuum lines o fuel rails o power steering o engine/oil coolers o HVAC components o Fuel filler necks o refrigeration Product Features Product Benefits High grade single wall strip materials are utilized to ensure optimized physical properties Provides ease of fabrication and can be expanded, compressed, flattened, cut formed or bent into almost any shape Most sizes available as welded, cold drawn, or annealed Enables low-cost material substitution Available in a wide variety of coatings & stainless alloys Provides a variety of low cost corrosion protection options to meet every application Conductive Nylon O. D. coated tube, with or without nickel I. D. , available Offers a replacement for many stainless steel and aluminum tubing applications Fluid and gas carrying capabilities at medium to high pressure Provides a wide range of product capabilities

Coatings Inner Sacrificial Layer Hot Dipped Alloy Layer consisting of 95% Zinc and 5% Aluminum Outer Barrier Layer None Other Info. Coating may be soldered. Contact TI Automotive for method description. Meets OEM Customer Specifications Daimler Chrysler PS-8688 Code NZ Ford Motor Company ESA-M 1 A 270 -A General Motors Corp. GM 123 M GM 124 M Code AG

PVF COATING Inner Sacrificial Layer Electroplated Zinc Layer Outer Barrier Layer PVF ( Polyvinyl Fluoride ) Paint Layer Other Info. Meets OEM Customer Specifications Daimler Chrysler PS-8688 Code PE Ford Motor Company WSK-M 2 P 139 -AESA-M 21 P 20 A

Process Of Production: 1. Material receipt 2. Tube Cutting 3. Deburring +Air blow 4. Swaging 5. 1 st End Forming 6. Sleeve Cutting 7. Nut/Sleeve Insertion 8. 2 nd End Forming 9. Marking/Sleeve Location 10. Sleeve Shrinkage 11. Inspection/Final Air Blow 12. CNC/Power Bending 13. Manual Bending 14. Leak Testing 15. Final Inspection 16. Packing/Storage 17. Dispatch

1. Material Receipt

2. Tube Cutting: Cut the tube with the help of power cutter according their length

3. Deburring+Air Blow During they cutting process the sharp edges are formed in the end so we remove the sharp edges. We use deburring process & air blow for remove dart particle in tube.

4. Swaging : During the deburring process the diameter of tube increases so we want to actual size of the diameter of the tube we use swaging process.

5. 1 st End Forming : After the swaging operation we form the first and of the tube using pressure punching machine. pressure which is use is 70 kgf/cm 2

6. Sleeve Cutting Some time we avoid the fuel pipe and break pipe from heat and corrosion we use sleeve pipe insert in the sleeve

7. Nut/Sleeve Insertion: After forming the 1 st end insert the nut and sleeve. This operation is held manually 9. Marking/Sleeve Location Marking the position of the sleeve in the pipe and inert the sleeve 10. Sleeve Shrinkage about 140 C. After insertion of the sleeve. The pipe is passes over the temperature and then sleeve shrink

11. Inspection/Final Air Blow Inspection for the cut and other fault like leakage

12. CNC/Power Bending The pipe is bend with the help of the CNC/Power bending according to their PLANE, FEED, BEND. Pressure is required for this is 6 bar 13. Manual Bending This operation is also done with the help of manual bending

14. Leak Testing This is for the test for leakage in the pipe. Fill the air in the pipe then pipe deepwater tank 15. Final Inspection 16. Packing/Storage 17. Despatch

Environment & Quality Environmental Responsibility In order to minimize its own impact on the environment, TI Automotive is seeking ISO 14001 certification on a global basis. This international standard sets criteria to ensure that an effective environmental management system is in place at each facility. We monitor our environmental performance closely and third party verification audits are conducted annually. With these aids we can assess our achievements and review our targets on a regular basis. Our aim is ongoing improvement so further developments are constantly being implemented. All eligible TI Automotive sites are ISO 14001 certified or working toward certification. Many of TI Automotive's products have positive environmental impacts in terms of emissions and noise reduction. We constantly monitor emissions legislation on a global basis. California's upcoming LEV II and PZEV standards are the current driver for evaporative emissions regulations, worldwide. These stringent standards are likely to serve as the model, with modifications, for future standards throughout the world. TI Automotive is committed to helping its customers meet LEV II, PZEV and other future standards with innovative, cost-effective, fuel system products.

Global Customer Base TI Automotive has a supplier partnership with every major Original Equipment Manufacturer (OEM) in the world. TI Automotive is able to maintain these relationships by continually adapting as the automotive industry's boundaries expand across the globe. Our global customer base includes the following companies:

BMW Honda Fiat Isuzu Hyundai Daewoo Ned car Ford PSA General Motors Renault Toyota

BIBLIOGRAPHY: www. Tiautomotive. com

Thanks…. No questions plzzz….