final report ravi.pdf

7/29/2019 final report ravi.pdf

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TRAINING REPORTJuly 22 August 6

Prepared by

Ravi Teja

Material Research

HGID


2/18

TRAINING SCHEDULE NEW JOINEES

S/No.

Training Equipment Used Trainer Time July

22 23 24 25 26 27 28 29 30 31 1 2 3 5 6 7

1Creep Testing &

Lubricant TestTesting Jig & Heat Oven

Adarsh

San

I Half

II Half

2 Microscope Analysis1.Equipment Knowledge

2.Analysis on sample

Amit

San

I Half

II Half

3 X-Rite Measurement

1. Spectrophotometry

2.Measurement and

Operation of Equipment

Manu

San

I Half

II Half

4

Paint Thickness

Measurement / Du

Pont Impact Testing

1. Equipment Know How

2.Sample Measurement

Practice

Manu

San

I Half

II Half

5 Bony Polymers VisitVisit to Bony Polymers for

MP tubes

Adarsh

San

I Half

II Half

6KNP Trial - Pearl

White SystemVisit To KNP Factory

Manu

San

I Half

II Half

7Fabric / Leather

Abrason testing

Leather , PU Leather ,

PVC Leather , Fabric

Study & Abrasion

Manu

San

I Half

II Half

8 Final ReportYokoyama San &

Yamamoto San

12:30

PM Final Report toYamamoto San &

Yoko ama San

Activity

1 / 17


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MaterialOverview

HES,SPECStudy

MaterialDevelopment

Part Testing

SamplePreparation

SampleTesting

Evaluation

Training Flow

2 / 17


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S.No. Training Item Content Result

6 Abrasion Testing

Test requirement ,test procedure,sample

preparation,result evaluation

evaluation of abrasion testing for evaluation

of any faabric of interiors

7 Du Point Impact Testing

Impact testing as per HES,test procedure,

speciemen preparation & testing

earne use o impact tester to eva uate t e

performance,and strength of plastic

materials as per their application

5 Paint Process, (L,a,b) significance,X-Rite

Learnt how to find paint reflection values

for different samples and analyse the data

as done at KNP visit

3

4 Functions, Changing Lens, Manual StudyMicroscope analysisFinding crack,microstructure analysis ,grain

structure of polymers/metals.

Air Cleaner Box Noise test Support Activity to Manu San

Learnt noise test is needed to evaluate the

the performance during actual work

conditions

Sample Preparation, test standard, Break

even point,results and correlation.Creep Testing2

Learnt how to find the break even point any

plastic under prolonged stress

Training Summary

HES: different polymer grades as application;

Sample preparation for testing and

evaluation;

DWG of Interior & exterior parts of cars

Learnt use & application of different

polymers/resins in cars as per the

requirements at each section; also

learnt material evaluation method for each

part

Plastic & Rubber Materials

-Interior & Exterior1

3/17Summary 3 / 17


5/18

1.1 Plastic Materials

o Interior Materials

o Exterior Materials

HES PP -

Interiors

HES PP-

Exteriors

5 / 17PP Materials Classification


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Test Steps

Test Car : BRIO 2013 model Unit : dB/RMS/A Fast

Speed vs Noise values are tabulated

Test Steps

Sample Preparation(80x40x3 mm3) Sample is fixed on the jig

Test the creep properties of a material,

when subjected to a prolonged tensile

or compressive load.

Temperature: 80 deg C

Checked for any cracks are formed

Distance from the origin point is taken Sample: Xenoy

2. Air Cleaner Box Noise Test1.

Creep Testing

50

60

70

80

90

100

0 2000 4000 6000

dB/RM

S/A

Engine RPM

VA Material

CurrentMaterial

I can find break even point of any plastic

material at particular temperature underprolonged stress in future

2

2

3

2

4

2

2210

11

2

tXa

b

aa

b

Checked the variation of noise vs engine RPM

for both VA & Current material and results wasOK

6 / 17


7/18

3.Microscope Analysis

S.no. Function Used

1. Remove Glare When areas with intense light reflection appear

white

2. Depth Composition When some parts of the image are out of focus

3. HDR When high colour gradation images are required

4. Sharpening Image To enhance contours in vivid colours

5. Markers To mark some specific area

6. Measuring angles ,Distance To get geometrical specs

7. Image Stitching To produce wide-view images.

Learnt how to use different functions in microscope that is present in HGID lab andapplied the same for the verification of corrosion in MP tube

Digital Microscope

VHX-1000 series.

20x , 500x, 1000x

7 / 17


8/18

JSR- 50X

With Cleaning- 50X

Without Cleaning- 50X

Zeon- 50X

Due to the difference in the results, a visit for counter-measure planned.

Test Results by HGID:

OK

Test Result by Bony Polymers:

NG

Without Cleaning

8 / 17


9/18

Welding SealingPrimary

Treatment

Electro

DepositionPrimer Base Coat Clear Coat

Paint Process

1.Degreasing

2.Surface Activation

3.Zinc Phosphating

PAINT TYPE L a b

SY43 93.14 -1.31 +8.75

79.09 -1.39 -1.29

77.72 -1.29 +1.10

SY12 95.02 -0.22 +7.76

84.94 +0.39 +8.12

The samples were types of white colour used in other companys car models

4.X-Rite Measurement: Multi-angle Spectrophotometer For colour measurement

Measures: Chromatic region parameters (L,a,b)

& Flop Index (F.I.) Angles: 15,25,45,75,110deg

Angles L a b

25

45

75

9 / 17


10/18

Model Angl

e

Bonn

et

Front

Bumper

Door Side

ViewMirro

r

Trunk Rear

Bumper

Roof

Honda

Amaze

25 52.9 34.1 61.3 47.8 68.9 47.8 44.7

60 80.7 91.7 92.2 84.8 90.8 84.8 76.9

80 94.9 72.2 98.3 95.2 98.2 95.2 93.3

Suzuki

Dzire

25 8.1 20.5 9.4 1.2 36.3 58.3 35.8

60 20.1 18.4 51.8 3.3 56.4 76.1 54.6

80 46.3 31.2 66.0 11.0 70 80.6 55.7

Hyund

ai

Verna

25 33.0 35.6 14.0 2.3 29.1 25.8 26.6

60 67.8 75.9 57.7 41.6 56.5 57.3 67.7

80 68.9 73.3 18.0 53.6 70.2 64.0 75.7

Understood the working of the instrument and took reading for three different cars at

different areas of the Exterior plastic parts after Molding.

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5 .Gloss Meter


11/18

Test Steps :

Sample Preparation

Loads used 500gm, 1000gm

Heights we have used 50cm,45cm,35cm Find the Break point

Convergence & Confirmation of result

Samples EX2 Machino Polymers India

6.Du Pont Impact

Test Samples

Observed no breaking of the sample till 4.9 joules and similarly in future I can find the breaking

point or maximum impact the material can absorb in deciding which material to use ( we want

maximum energy to absorb instead of cracking, as while minor accidents also it should not bedamaged)

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5. Abrasion Testing

NGOK

Crack observed with

peeling at edges

Test Process

Cutting & preparation of test samples as

per spec HES D6506

Prepare samples for Wet Gakushin or Dry

Gakushin

Loading & setup of equipment and startcycles -30,000 for dry & 1000 cycles for

wet Gakushin

Evaluation of Result by checking the

Appearance & peeling as given in Spec

Sample Used 2TP Seat Fabric

2.Rotary Type Abrasion Tester

Test Process

Cutting & preparation of test samples as

per spec (Diameter of sample used

115mm)

Loading & setup of equipment and start

as per given spec Clean the abrasive wheels by sand

paper after every 1000 cycles for 20

rounds

Evaluation of Result by checking the

abrasion as per the grades in given spec

Sample Used2TP Seat Fabric

Test Sample

Observed

some peeling

1.Gakushhin type friction Tester

From this we can simulate the rupture between human body with the seats and liquids that maypour on seats sometimes

12 / 17


13/18

Title : Bony Polymers factory visit

Contents:

Processing of MP tubes

Cleaning of Extruder

Purpose : To understand the processing of MP tubes and Cleaning of Extruder

Conclusion: Bony Polymers visit is very satisfactory and one flaw found is there is

no clear work instruction for cleaning is attached near instrument. Learnt the processing of tubes

Why cleaning is very essential in Extruder

Meeting Date 31 July13

Meeting Place Bony Polymers

HGID Member. Yamamoto , Manu

san, Adarsh San,

Shuchi san

Compound

Storage

Extruder

Cleaning

Hopper

Feeding

Extrusion Knitting Adhesives Cooling

Antisticking

Speedcontrol Cutting Curing cleaning

Removal ofexisting materialfrom barrel head

Removal ofexisting material

from hopper

Removal of existingmaterial from barrel

Cleaning ofthe nozzle

Feeding thenew material

Removal offirst few (5-10)

tubes withimpurities

Summary- Visit 13 / 17


14/18

Title : Kansai Nerolac Paints factory visit

Contents:

Process

Purpose : Pearl White Trial

Conclusion:

In case of Mica Base we observed both DFT & Pigment Conc are effecting, So we need to

control both to make optimization In case of Base Coat there is no significant effect observed

Concluded Mica Base is a key parameter

Meeting Date 1 Aug13

Meeting Place KNP Bawal

HGID Member. Yamamoto , Manu

san, Manu san,

Shuchi san

Summary- Visit

IC White BakingNH-624

CBCC Baking

0

0.5

1

1.5

2

2.5

3

0 5 10 15

FI

DFT

MB FI vs DFT

20% UP

STD

20% Down

Series4 60

70

80

90

0 5 10 15

L

DFT

BC L(75) vs DFT

20% UP

STD

20% Down

Series4

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Seminars / Tasks

S.No. Date Topic Given By

1. 20 July,2013 Introduction to Polymers &Rubbers Adarsh San

2. 22 July,2013 Limit Strain Test Method Adarsh San

3. 24 July,2013 Colour Comparison of Car Models Manu San

4. 25 July,2013 Paint application Manu San

5. 25 July,2013 Paint thickness measurement Manu San

5. 26 July,2013 2MD Parts Investigation Manu San

6. 26 july,2013 Thermal Cycle Test Spec for Plastic

Materials

Manu San

7. 30 July, 2013 Initial R-theme Proposal Manu San

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Training

Conclusions: The training is very helpful in first-hand experience of works at HGID.

The exposure to various plastic and rubber materials used in cars will bebeneficial in the future working.

Material knowledge, testing and process know-how which learnt dailyfrom the mentors are essential to any R&D, and hence will be useful in

the future.

Study of various test methods and their importance is necessary forfuture localization & development ,and will try to contribute to HGID.

Study of fabrics/plastics/rubbers will help to apply it in the future materialsfor Honda Cars.

Will try to Give my best contribution to HGID, with the knowledge andexperience gained through the training.

16 / 17


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Acknowledgements Thanks to Yokoyama San and Yamamoto San :

For their continuous guidance and support,

And hope to learn more from them in the future.

Thanks to Adarsh San and Manu San: For their mentoring, daily training and introduction to the

HGID culture.

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final report ravi.pdf

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