Professional Documents
Culture Documents
INDUSTRY REPORT
CHAPTER-1: INTRODUCTION
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COMPANY
MARKET SHARE
(%)
HERO
53.85
45
TI
28.83
24
ATLAS
28.3
24
OTHERS
7.6
6
Table 1.1(a)
Table 1.1(b)
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India is the second largest maker of bicycles in the world. Around 9 million
bicycles (valued at Rs. 1500 crore) are produced each year. Ludhiana has been
the primary source of components for the cycle industry in India. Recently,
Vendor bases have come up in other parts of the country thereby diluting the
geographical risk.
Fig 1.1(a)
Table 1.1(c)
CAGR- Compound Annual Growth Rate
SLR- sports light roadster
MTB- mountain terrain bikes
In last 6 years, specials have posted a higher CAGR on the back of product
innovations and pricing.
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The domestic demand in India for the cycles majorly comes from rural areas. In
India more than 60 percent of population resides in rural areas which are
characterized by poor infrastructural facilities and low income groups. These
areas lack the concrete roads and the dirt roads often get damaged during
monsoons. Therefore, the rural population demand bicycle more than motor
driven vehicles. In rural area bicycle is one of the most important modes of
transportation for middle and low income groups.
Fig 1.1(b)
Threats to the industry
Emerging Economies are becoming volume drivers with their associated costs,
quality and productivity advantages.
Solution for high volume and world class quality at low costs.
Like in many other sectors, the Chinese threat seems to have been overstated in
the cycle industry.
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1.2 Bicycle
Bicycles were introduced in the 19th century in Europe and, as of 2003, number
more than a billion worldwide, twice as many as automobiles. They are the
principal means of transportation in many regions. They also provide a popular
form of recreation, and have been adapted for use as children's toys, general
fitness, military and police applications, courier services, and bicycle racing.
The basic shape and configuration of a typical upright, or safety bicycle, has
changed little since the first chain-driven model was developed around 1885.
But many details have been improved, especially since the advent of modern
materials and computer-aided design. These have allowed for a proliferation of
specialized designs for many types of cycling.
The bicycle's invention has had an enormous effect on society, both in terms of
culture and of advancing modern industrial methods. Several components that
eventually played a key role in the development of the automobile were initially
invented for use in the bicycle, including ball bearings, pneumatic tires, chaindriven sprockets, and tension-s poked wheels.
1.2.1 History
Fig 1.2(a)
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1.2.2 Nomenclature
Fig 1.2(b)
1. Seat tube
2. Down tube
3. Head tube
FRAME
4. Top tube
5. Seat stay
6. Chain stay
7. Fork
8. Saddle
9. Derailleur
10. Chain
11. Crank
DRIVING PARTS
12. Pedal
13. Spokes
14. Rim
WHEEL ASSEMBLY
15. Tyre
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Roadster: are designed for commuting, shopping and running errands. They
employ middle or heavy weight frames and tires and they often have internal
hub gearing. To keep the rider clean, they often have full front and rear fenders
and chain guards. To make the bike more useful as a commuter vehicle, they
are often equipped with a basket. The riding position varies from upright to
very upright.
Mountain bicycles (also called All Terrain Bicycle) are designed for off-road
cycling. All mountain bicycles feature sturdy, highly durable frames and
wheels, wide-gauge treaded tires, and cross-wise handle bars to help the rider
resist sudden jolts. Some mountain bicycles feature various types of
suspension systems (e.g. coiled spring, air or gas shock), and hydraulic or
mechanical disc brakes. Mountain bicycle gearing is often very wide-ranging,
from very low ratios to mid ratios, typically with 16 to 28 gears
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1.3.2 History
A man who had a dream to provide quality bicycles to his countrymen at reasonable
prices. The man Shri Janki Das Kapur. The dream: Atlas Cycle Industries Ltd. A modest
beginning in an improvised shed at Sonepat. This was transformed into a 25 acre factory
complex in a record period of 12 months in 1951.
In the very first year of operation, 12000 Atlas Cycles rolled out of the plant. Its no
looking back since then. Soon, the first consignment of Atlas Cycles was sent overseas
in 1958. Atlas has since then exported to several countries.
By 1965, Atlas had emerged as India's largest cycle manufacturer. Greater demand,
higher production and ever-expanding markets made Atlas a name to reckon with. Atlas
introduced the first racing Bicycle in India in 1978.
It was time for accolades. Atlas was presented with the FICCI Award for 'Best Industrial
Relations'. Atlas' growing importance in the international arena did not go unnoticed
either. Italy's Gold Mercury International Award was conferred on Atlas. Subsequently,
it also received the prestigious EEPC Award for export excellence and is the recipient
of several other accolades and awards in various categories.
The honour of being appointed official supplier of bicycles to the IXth Asiad, at Delhi
in 1982, added another feather to Atlas' cap. With growing demand for its products,
came the need for achieving self-sufficiency in specialized bicycle components. To
meet its entire steel tube requirements the Atlas Steel Tube mill was set up at Gurgaon.
Not only was dependence on external suppliers broken but the stringent quality
controls, synonymous with Atlas, were maintained and the journey still continues...
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Following closely on the foot-steps of his illustrious father Shri Janki Das Kapur Ji,
Shri Jai Dev Kapur worked hard to take Atlas to new heights of achievement year after
year. He was pioneer in establishing, the Atlas Cycle Industries Ltd. Sonepat, way back
in 1951 with completely indigenous know-how and expertise. Due to restructuring of
the Atlas Group of Industries in 2003, Shri Jai Dev Kapur was appointed as the
President of Atlas Cycles (Haryana) Ltd, Sahibabad (U.P), an ISO 9001-2008 certified
company. Shri. Jai Dev Kapur was also the Director of Milton Cycle Industries Limited,
Sonepat. He served as the President of All India Cycle Manufacturers' Association and
Sonepat Productivity Council several times and fought for the cause of bicycle industry
on various government forums.
A firm believer in progressive management and scientific techniques, Shri Jai Dev
Kapur led a number of Atlas export promotion delegations abroad. It is as a result of
his efforts that Atlas has emerged as a leading exporter of bicycles and bicycles
components. Today Atlas bicycles are being exported to several countries.
In spite of his administrative and executive pre-occupations, Shri Jai Dev Kapur got
associated with various charitable, religious and humanitarian works. Under his able
leadership and guidance, Atlas cycles got a new look from conventional to more
contemporary which reflects the culture of the company of being innovative and
progressive.
Atlas will always follow his illustrious footprints...
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1.3.4 PHILOSOPHY
1.3.4 Management
Before moving to Sahibabad, Mr.Girish Kapur was looking after
several critical functions at Atlas, Sonepat. His focus on providing a
superior quality affordable product for the common man is well known
in the industry. He also established Atlas Steel Tube Industries,
Gurgaon. He was also the President of All India Cycle Manufacturers
Association (AICMA) during 2008-09 and under his leadership the Association took
several bold and noteworthy initiatives.
Prior to joining the Sahibabad unit, Mr. Gautam Kapur credibly
looked after the entire International marketing operations of the
company at Atlas, Sonepat. His proficiency in this area is well
acclaimed and will remain an asset in forging future International
business alliances. Additionally he also managed affairs of Milton
Cycle Industries Ltd, Sonepat. Mr. Gautam Kapur is trustee of Dewan Harnam Das
Memorial Trust and Sheila Kapur Memorial Trust. He was also the Vice President of
Indo-Myanmar Chamber of Commerce and Industries.
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Atlas is also conscious of its social obligations. Atlas has always been associated with
charitable, religious and humanitarian works. It has got long association with Dewan
Harnam Das Saraswati Devi Trust and Sheila Kapur Memorial Trust, Shri Narsingh
Das Hira Devi Trust, New Delhi, Shri Swami Satyanand Dharmarth Trust, New Delhi
and Dharamshila Cancer Foundation and Research Centre, New Delhi. Shri Swami
Satyanand Dharmarth Trust is engaged in the religious activities in the country. Dewan
Harnam Das Saraswati Devi Trust is running a well-equipped Hospital and a Public
School at Sonepat. All these Trusts have been doing laudable work for the emancipation
of the poor, needy and downtrodden. These institutions carved out a name for their
efficiency and standard.
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Atlas, Sahibabad bagged 1st prize at All India Industrial Exhibition, Hyderabad
- Feb 2014view more
Gold Meet organized for Tamil Nadu dealers - Nov 2013view more
Atlas, Sahibabad participated in Cycle Trade Fair, Patna & IITF, Delhi &
bagged third prize at IITF. - Nov 2013view more
Gold Meet organized for UP & Uttarakhand dealers - Oct 2013view more
Atlas Cycle race for boys & girls organized on 20th Sep & 23rd Sep 2013
respectively at Chandausi (UP) view more
Appointed official supplier of bicycles to the IXth Asiad held at Delhi in 1982
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and
material
removal
processes.
Machinig
processes
Forming
-
Fabrication
Rolling
Forging
Sheet
metal
operations
Material
treatment
-TIG
welding
-MIG
welding
Material
removal
phosphate
treatment
brazing
debrazing
Drilling
Grinding
Milling
threading
Fig 2.1(a)
No-one ever wonders how that simple structure peddled away on the streets
would require such complex processes as rolling, bending, cutting, fitting,
welding, grinding, metal treatment, etc.
Firstly though, the need of all the departments and their interdependency
should be well understood; as all the departments mentioned above need to
work and function effectively and efficiently to produce a product which is
appreciated and well accepted by the customer.
The flow chart best indicates the flow and control of material by various
departments and how they end up producing a final product.
Note: Production Planning and Control (PPC) forms the backbone of all processes
as it controls all the processes from purchase up to despatch.
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Happy customer
Despatch
Store
Assembly and
packaging
Store
Production
Store
Purchase Dpt.
Quality checks
Fig 2.1(b)
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Firstly the orders of the total items that need to be produced is confirmed by
PPC dept. via information collected from the sales department.
Next up, PPC plans the production chart for the day by observing data such as
materials to be purchased, parts to be purchased, inventory stock, etc.
Quality check is done for the material and component being received at the
incoming Dpt. and material received certificate (MRC) is produced. After
successful verification of the quality by quality inspectors, materials and parts
are handed-over to the respective departments for further machining, joining,
painting or assembly.
Steel sheets and steel tubes which form major part of the purchase; once
quality checked are stored in the store unit. Tubular department issues these
raw materials in order to start with its production after analysing the
requirement on the production plan, and performs the following two tasks:
1. Production of frame.
Steel tubes are machined and fitted to brackets to produce the
required quadrant frame which forms the basic structure for the
bicycle. In addition to this, the chain stay and seat stay supports
are also constructed via bending and machining other steel tubes
of varying dimension, which finally take their place as an
supplement to the frame.
Fig 2.1(c)
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2. Production of mudguard.
The steel roll is rolled to form and cut to final length; consequently
machining is done to produce the final mudguard.
Fig 2.1(d)
After construction of the parts, these are taken for brazing to ensure proper
metal joining and cleansed for proper adhesion of the paint compound.
Fig 2.1(e)
The tubular unit forwards these cleansed parts for painting via loading the parts
on conveyer. Before Paint Dpt. starts with its process, the parts need to be
taken through phosphating unit to prepare a smooth and even surface for the
painting to be flawless.
Fig 2.1(f)
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Correspondingly other parts of the frame (such as the fork end, wires, carriage,
etc.) and different variety of frames (depending on the classification of
bicycle) are issued from storage. These parts are again cleansed and machined
for proper fitting.
Now the paint shop is ready to perform its function of painting by following
three methods:
1. Manual spray painting
2. Dip painting
3. Electrolytic spray painting
Basic procedure for painting for the above processes described is as follows:
Again bake
and clean the
parts
After curing
again put base
coat
Note: The procedure is followed by careful quality checks at each stage. Moreover the
procedure is followed principally the same for 3 of the listed methods.
After achieving successful paint thickness and required quality, the frames
previously produced are loaded onto the conveyer and others are carried via
trolleys to the assembly unit.
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Finally the seat pillar is attached and the unit is loaded onto the conveyer and
sent to storage unit.
For varying frames some additional assembly is followed like shocker fitting
and carriage fitting, rest procedures are followed similar to the above point.
Fork ends are separately assembled with crown and cover fitting; finally
packed and moved to storage unit.
It records and maintains a copy of the records which include various charges,
services performed, expenses, inventory and other dispatch information.
The packed units are finally loaded onto the trucks issued by PPC during
production planning according to the order. Hence these loaded trucks drive
through and units reach out to the respective dealers according to their demand
initially placed.
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Bicycle frames have to be built to handle a variety of loads. First, the frame
needs to support itself and other components of the bicycle. These are
considered static loads. In addition, the frame needs to be able to handle the
cyclist's weight, the forces of pedalling and braking, and the effects of the
road's surface. These are dynamic loads which move and vary in intensity.
The most popular frame design which stands up on all regards of the above
forces are the diamond or double- triangle. It's proven to be a great use of
materials, great for bracing angles, great for strength; it lends itself to being
beat up pretty hard and still being ridable.
The company deals in variety of frames but the ones indigenously built are of
sizes 20/22/24.
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Frame consist of steel tubes with grade ERW C1, ERW C2, ERW C3. The
following table descripts all the necessary properties which are dealt with
during material selection. Suitably according to the segment of bicycle being
manufactured steel tubes are ordered to a vendor.
Table 2.2.1(a)
Once the respective tubes (i.e. bottom, seat, head, top, seat stay and chain stay)
of necessary dimensions and grade are procured, they are received from the
storage and on goes the machining operations to prepare the frame.
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Seat Tube
B. B. Shell fitting
Punching
Lug fitting
Bottom Tube
Head Tube
Grinding
operation
Notching
Liner fitting
Top Tube
1. Grinding
Def. is a metal cutting operation performed by means of abrasive particles rigidly
mounted on a rotating wheel, it is used to finish the work pieces with extremely
high quality of surface finish and accuracy of shape and dimension.
Machine used: Bench grinder
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2. Lug fitting
Def. These are socket-like sleeves which fit over the ends of the tubes and help
connect the steel tubes of frame.
Consecutively brazed with a silver or brass filler metal
Importance
The lug greatly increases the strength of the joint by distributing the molten filler
metal over a larger surface area via capillary action.
4 lugs which may be used to construct a typical diamond frame include:
Seat lug joins the top tube and seat tube; the ends of the seat stays are usually
brazed directly to the sides or back of the seat lug.
Bottom bracket shell joins the chain stays, seat tube, and down tube, and
includes a threaded cylindrical socket for the bottom bracket
Upper head lug joins the head tube and top tube
Lower head lug joins the head tube and down tube
Head lugs
Seat lug
B. B. shell
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4.
Punching
Def. It is a cutting process in which material is removed from a piece of metal by
applying a great enough shearing force.
Machine used: Punch press
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5. Notching
Def. It involves combining a punch press with a specialized punch die to reshape
the end of the tube. Notching allows for assembly of tubes with a tube connector
or welder.
6. Liner fitting involves manually fitting a cylindrical metal plate inside the tube to
provide the tubes support while various machining operations take place. It
prevents the inner surface of the work piece.
Liner
Steel tube
Operation carried out by manually fitting the liner inside the tube using mallet.
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With all the necessary operations in place, frame of the bicycle is constructed
by putting the tubes in a gauge set to correct dimensions. The lugs are held in
place by clamps, in which tubes are pressed and fitted.
After obtaining the quadrant structure in position, tack welds are used.
Importance
Tack welds are temporary means to hold the components in the proper
location, alignment, and distance apart, until final welding can be completed.
Several tack welds are made at some distance from each other to hold edges
together. It performs the following functions:
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The head tube joint and seat tube joint are taken for a dip in molten brass
furnace to prepare strong joints and then cooled and stacked in position.
BRAZING
THEORY: It is the joining of metal to metal, by filling the joint with a
different, melted metal at temperatures over 840F. The melted metal filling the
gap must be able to wet the pieces being joined so that it is drawn into the gap
by capillary action. The pieces being joined together are referred to as the base
metal, while the melted metal that fills the gap between them is called the filler
metal.
Filler metal used is a golden coloured metal called brass. Brass melts at a much
lower temperature (1600 F) than steel (2300). As you approach a metal's
melting point, the metal crystallizes, and its alloys can separate. So, if you can
stay well below the metal's melting point, you'll end up with a stronger
attachment.
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These include the seat stay tube and chain stay tube.
The seat stays connect the top of the seat tube (often at or near the same point
as the top tube) to the rear fork dropouts. On most seat stays, a bridge or brace
is typically used to connect the stays above the rear wheel and below the
connection with the seat tube. Besides providing lateral rigidity, this bridge
provides a mounting point for rear brakes, fenders, and racks. The seat stays
themselves may also be fitted with brake mounts. Brake mounts are often
absent from fixed-gear or track bike seat stays.
The chain stays run parallel to the chain, connecting the bottom bracket shell
to the rear fork ends or dropouts. Occasionally (principally on frames made
since the late 1990s) mountings for disc brakes will be attached to the chain
stays. There may be a small brace that connects the chain stays in front of the
rear wheel and behind the bottom bracket shell. Chain stays may be designed
using tapered or un-tapered tubing. They may be relieved, ovalized, crimped,
S-shaped, or elevated to allow additional clearance for the rear wheel, chain,
crank arms, or the heel of the foot.
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Cleaning
Bending
Liner fitting
Trimming
and pressing
Bridge
welding
Side cutting
End rounding
Spot welding
tapping
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Process starts with loading a tube into a pipe bender and clamping it into place
between two dies, the clamping block and the forming die. The process of tube
bending involves using mechanical force to push stock material pipe or tubing
against a die, forcing the pipe or tube to conform to the shape of the die.
Machine used: Power press
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4. BRIDGE WELDING:
Between two chain stay and seat stay tubes are welded a metallic bridge
element to provide lateral rigidity using TIG welding.
This is done by mounting the tubes on a fixture and suitably welding is done
over the sides of bridge to the tube surface.
6. Tapping: It is the process of cutting a thread inside a hole so that a cap screw
or bolt can be threaded into the hole.
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After all the necessary operations concluded, chain stay and seat stay pair
making takes place. The pair of stays are mounted on the jig where these are
mated to the brazed frame after bolting/welding the pairs together.
After the frame is ready it is sent for debrassing as the brass adhering to the
joints may hinder the painting process thus the structure is dipped into various
tanks with solutions TSP(tri- sodium phosphate), normal water, sulphuric acid
and sodium nitrate.
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It is a part of the cycle which frames up the wheel well. Its primary purpose is
to prevent sand, mud, rocks, liquids, and other road spray from being thrown
into the air by the rotating tire.
A cycle has primarily single pair of fender; one at front and other at the rear.
The rear fender runs from the chain stays all around the rear tire until it is
pointing almost straight down at the back. These have two pairs of stays (wire
struts) to hold the rear part in position, and also attach to the seat stay and chain
stay bridges.
The corresponding front fender extends from about 6 inches in front of the
fork, rearward and down well below the "equator" of the front wheel, again
with stays. Ideally, the front should also be equipped with a mud flap to protect
your feet and the chain wheels from spray.
Material is received form the store for producing front fender, rear fender and
clip in the form of steel sheets which are followed by rolling procedure to cut
the formed sheets to fender shape.
After all the necessary operations the part goes through the procedures of
inspection and handed over to the paint shop.
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REAR FENDER
Hole for
reflector
FRONT FENDER
Roll to form
Cut to final
size
Punching
End bending
Pressing
Fit clipping
Spot welding
1. Roll to form: flat steel sheets are cold rolled with help of rollers to bend
them to necessary shape and then cut to final size required.
Fig 2.2.1(t)
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Fig2.2.1(w)
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The facility is equipped with a fully automatic paint shop with pre-treatment
plant for painting of Bicycle frames, forks, Chain cover, Mudguard etc.
Pre- treatment is a crucial phase which prepares the parts for maximum paint
adhesion by creating a immaculate surface. It basically has 2 parts:
Pre-treatment
Pickling
Phosphating
and aluminium alloys. A solution called pickle liquor, which contains strong
acids, is used to remove the surface impurities. It is commonly used to descale
or clean steel.
Scale consists of thin layers of iron oxide crystals, of which the chemical
compositions, structures, and densities vary according to the temperature,
oxidizing conditions, and steel properties that are present during their
formation. These crystals can be dissolved by acids; normally, hot
hydrochloric or sulphuric acid is used. In addition, inhibitors are added to the
acid to protect the steel from being dissolved as well.
Process is operated by dipping the parts for a predefined time in a line of tanks
as high as 25 to 30m containing acid and neutraliser. Each maintained at
constant temperature and concentration.
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2.2.2.1.2 Phosphating
Phosphate coatings are used on steel parts for corrosion resistance, lubricity,
or as a foundation for subsequent coatings or painting. It serves as a conversion
coating in which a dilute solution of phosphoric acid and phosphate salts is
applied via spraying or immersion and chemically reacts with the surface of
the part being coated to form a layer of insoluble, crystalline phosphates.
The application of phosphate coatings makes use of phosphoric acid and takes
advantage of the low solubility of phosphates in medium or high pH solutions.
Iron, zinc or manganese phosphate salts are dissolved in a solution of
phosphoric acid. When steel or iron parts are placed in the phosphoric acid, a
classic acid and metal reaction
takes
place
which
locally
depletes
the hydronium (H3O+) ions, raising the pH, and causing the dissolved salt to
fall out of solution and be precipitated on the surface.
The following is a typical phosphating procedure:
o Cleaning the surface
o Rinsing
Water
o Surface activation
HCL
o Phosphating
Temperature 65 to 75C
o Rinsing
D. M. water
Passivation
coatings
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With completion of surface treatment, parts are transferred for the painting
processes.
Painting
Manual Painting
Electrolytic
spray Painting
Dip Painting
Disc plant
Bell plant
Choice of method is attributed by the paint being used. The plant used the
following criteria:
METHOD
MECHANISM
PAINT TYPE
PARTS
Spray painting
mudguard,
containers
temperature
mudguard
having paint.
260C)
stands
frames,
forks,
mudguard.
guns
160C)
Table 2.2.2(a)
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It is a process in which the part is simply dipped into a bath of high bake paint
and consecutively pulled out and loaded on a conveyer which transfers them
to a dryer, where they get dried.
at a constant speed.
o Start-up:
The part has remained inside the solution for a while and is
o Evaporation:
Hole punched
for name plate
Name plate
fixed using
rivet
Place gold or
silver linings
on the
boundary
Wrapped with
crape
paper
and part put
inside
polythene
Another coat
of white paint
on part of
mudguard
After suitably
baking the
paint sticker
is put on
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This process occurs when paint is applied to an object through the use of an
air-pressurized spray gun. The air gun has a nozzle, paint basin, and air
compressor. When the trigger is pressed the paint mixes with the compressed
air stream and is released in a fine spray.
Due to a wide range of nozzle shapes and sizes, the consistency of the paint
can be varied. The shape of the work piece and the desired paint consistency
and pattern are important factors when choosing a nozzle.
The three most common nozzles are the full cone, hollow cone, and flat stream.
There are two types of air-gun spraying processes. In a manual operation
method the air-gun sprayer is held by a skilled operator, about 6 to 10 inches
(1525 cm) from the object, and moved back and forth over the surface, each
stroke overlapping the previous to ensure a continuous coat.
In the department such manual air spray is also used to paint portions of the
parts which are unreachable by the automated spray painting device.
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2.2.2.2.3.
INDUSTRY REPORT
This is a type of automated spray painting method which works on works on the
principle of electrolysis. The object being painted is usually placed on rollers or
a turntable to ensure overall equal coverage of all sides.
and is
the work
piece by a
The work piece travels down a conveyor belt towards a paint booth, or paint
tank, where it is sprayed with, or dipped into, electrostatically charged
paint particles. Integrated into a powder paint booth is a powder recovery unit,
which recovers between 95% and 100% of the paint over-spray coatings. After
the work piece is coated, it continues on the conveyor belt to an oven, where the
paint is cured.
The benefits to the process of electrostatic coating is the ability to recover the
little over-spray and having the process automated which will cut costs. The
reason for the little over spray is the paint particles that do not hit the piece will
turn in the air and go back to the piece. There are also some drawbacks to the
process everything in the area of the coating must be grounded to prevent static
build up and can easily arc, damaging the hanging devices and/or the locations
where the hanging devices rest on the conveyor.
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INDUSTRY REPORT
Due to the occlusion of electrostatic, the lost paints are sucked back to the
workplace in generating a kind of surrounding electrostatic effect and the over
spraying phenomenon is thus minimized. In this way, the atomization of this
method is excellent as is the transfer efficiency. This method also can be used
with paints of different viscosity. Therefore the machine has achieved the
purpose of electrostatic coating.
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INDUSTRY REPORT
In using the liquid electrostatic spray gun, the high compress air tends to throw
the paint away when the paint passes through the special nozzle, the droplets
pick up the charge from an electrically charged electrode at the tip of the gun
by charged electrode.
The charged particles are given their initial momentum from the fluid
pressure/air pressure In this case, the expelling effect appears between the
paint carrying electrostatic and the live particles as to cause further atomization
of paint and thus, forming much finer thin fog. Due to the occlusion of
electrostatic, the lost paints are sucked back to the workplace in generating a
kind of surrounding electrostatic effect and the over spraying phenomenon is
thus minimized. In this way, the machine has achieved the purpose of
electrostatic coating.
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INDUSTRY REPORT
The typical bell applicator consists of five major assemblies: the valve module,
the bell cup, the turbine, the shaping air shroud, and the electrostatic system.
The valve module is a manifold consisting of passages for paint, solvent, and
compressed air, and valves to control the flow of materials for paint delivery,
cleaning and purging with solvent, and management of compressed air to the
valves, turbine, and shaping air shroud.
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INDUSTRY REPORT
The bell cup is a conical or curved disc fixed to the shaft of the turbine. Paint is
injected into the centre of the rear of the disc, and is atomized by being forced
out to the edge of the cup by centrifugal forces. The flow of the paint over the
cup and off the edge breaks up the paint into atomized droplets.
The turbine is a high speed, high precision air motor that rotates the bell cup at
speeds ranging from 10,000rpm to 70,000rpm, depending on the cup diameter,
atomization desired, and physical properties of the paint. Typical turbines for
this application use an air bearing, where the spinning shaft is suspended in a
cushion of flowing compressed air, with virtually no frictional resistance.
The shaping air shroud, or shaping air ring, is simply a ring with passages for
air to flow out the front of the atomizer, outside of the cup diameter, to manage
the size of the spray pattern produced. As more air is forced through the shroud,
the atomized paint is forced into a smaller pattern.
The electrostatic system can be internal or external (or direct or indirect charge),
and supplies high voltage (30,000 to 100,000 volts DC) charge to the applicator,
or the air surrounding it. This has the effect of negatively charging the paint,
while causing a region of positive charge to form on the work piece, resulting
in electrostatic attraction between the paint and the work piece. The electrostatic
system is visible only on an external (or indirect) charge applicator, where it
appears as a series of 4-8 forward-facing electrodes in a circular array around
the bell. It is typically called a 'candelabra' for its resemblance to one.
The paint is fed to bell shaped applicator rotating at high speed (6000 rpm). The
paint particles are atomized due to high rotation speed. The paint particles are
negatively charged (at 100kV) and these follow the spray pattern generated due
to the air shower and deposit on the article. Transfer efficiency is very high and
may reach 90%.The bell is also used in powder coating.
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INDUSTRY REPORT
Painted parts are conveyed to the assembly department after necessary quality
checks.
Here all the parts/components are brought together to form a single product
i.e. bicycle.
Sticker placing
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INDUSTRY REPORT
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INDUSTRY REPORT
Identification sticker is put over each frame, followed by painting the frame
number near the seat tube opening.
Sticker put on
the legs of the
part
Plastic cover
put on the
head of tube
Turning
done to fit
crown cover
Crown fitted
using a
pneumatic
press machine
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INDUSTRY REPORT
Types of QC:
Quality check
Incoming
Final/ intermediate
If the material is not up to the standard it is sent back to the vendor and an
inspection is carried out over the subsidised material.
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INDUSTRY REPORT
Table 2.2.4(a)
Vernier calliper
Thickness gauge
Bevel protractor
Bore gauge
Ring gauge
receiving fixtures
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TEST AIM
Kinetic test
for pedal
Handle
dynamic test
Fork
vibration test
Saddle
fatigue test
Tensile
strength
machine for
spoke
Tyre
abrasion test
Chain
breaking test
Tire tube
tensile test
Impact load
test
INDUSTRY REPORT
PROCESS
Mass suspended over each
pedal on a assembled pair
of pedal via test shaft
Handle is delivered with
continuous vibrations while
being fixed over a fixture.
Fork is delivered with
continuous vibrations under
a load of 3 kg on each leg
for duration of 1.1 hours
while being clamped on a
fixture.
Big size saddle
Load of 70kg mass
Children saddle
Load of 50 kg
Load to be applied at rate of
150 strokes/min for total
70000 strokes.
FREQUENCY
REQUIREMENT
OF TEST
Every month
There should be no
noticeable fracture after
1000000 cycles
Every month
No fracture/ crack to
appear on the bar handle
and stem.
Every 15 days
No visible fracture on the
fork leg joints.
Every month
No abnormality
No deformation
On saddle top and other
parts.
Every lot
Every 15 days
Every lot
Every 15 days
Tensile strength=
breaking load/ area of
dumble piece(w x t)
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Elongation%= {(L2
L1)/L1}x100
Every month
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Rim vertical
load
INDUSTRY REPORT
Deformation <2.5mm
Table 2.2.4(b)
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INDUSTRY REPORT
Also keep a check on the availability of various parts and spares in inventory.
Diesel generator
Boilers
Chilling plant
Compressors
Air blowers
Bell plant
Power presses
Rolling machine
Drill machine
Tapping machine
Grinders
Shaper
R. O. plant
Lathe
Milling machine
Spray guns
Pumps
Welding machines
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Yearly
Daily
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INDUSTRY REPORT
CHAPTER-3: PROJECT
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INDUSTRY REPORT
It is feature based, parametric solid modelling design tool that takes advantage
of easy to use Windows graphical user interface.
You can create fully associative 3D solid models with or without constraints,
while using automatic or user defined relations to capture design intent.
Process:
All drafted designs for various parts were provided. It included drawings for the
frame, fork, chain stay, seat stay support tubes, crank assembly, and carriage.
After determining the views from all directions, the product was
conceptualized, visualised and initiated with.
Before any model can be developed, first task remains of creating a profile and
successfully constraining it to the required dimensions.
Commands used for creating a profile included drawing lines, points, circles
and ellipses.
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INDUSTRY REPORT
Fig 3(a)
After creating basic profiles, various features can be clubbed with it to develop
a body by adding necessary material over the profile or removing it, whichever
be the case.
Fig 3(b)
Some commands used:
1. PAD: sketch based feature that adds material to a model.
2. POCKET: sketch based feature that removes material from the model
3. SHAFT: revolve based feature that adds material to the model
4. GROOVES: revolve feature that removes material from existing features by
rotating a 2D profile around axis.
5. RIB: it is a positive solid that is generated by sweeping a profile along a centre
curve.
6. SLOT: It is a negative solid that is generated by sweeping a profile along a
centre curve.
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INDUSTRY REPORT
Fig 3(c)
PART
MODEL
Frame
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INDUSTRY REPORT
Carriage
Peddle
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INDUSTRY REPORT
Saddle
Crank assembly
Wheel
Table 3(a)
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INDUSTRY REPORT
Top
front
Side
Isometric
Fig 3(d)
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INDUSTRY REPORT
CHAPTER-4: CONCLUSION
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INDUSTRY REPORT
During the period of this project I studied about the different type of machinery
and processes that are essential for production of the various components related
to a bicycle. The production is broadly for the manufacturing of the sports light
roadster cycles (SLR) and specials which take up the maximum production
owing to the huge customer demands. Besides it, the remarkable coordination
between all the departments to keep the production running effectively and
efficiently was substantial.
The project I worked upon was modelling a full size bicycle in a CAD software,
which would help visualise the product on various grounds such as design
ergonomics, aerodynamics, stress analysis, fatigue tests, factor of safety of the
structure, etc. This could actually cut down various expenses owing to the
prototyping stage while developing a new product.
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INDUSTRY REPORT
BIBLIOGRAPHY
http://www.atlascycles.co.in/
http://www.atlascycles.co.in/
http://www.atlassteeltubes.com/about_clients.asp#Bicycle%20Applications
http://ticycles.com/
http://www.miltoncycles.com/index.asp
http://en.wikipedia.org/wiki/Bicycle
http://www.mbarendezvous.com/cyclecasestudy.php
http://www.rivbike.com/kb_results.asp?ID=32
http://curbdestroyer.blogspot.in/2011_09_01_archive.html
http://www.smithy.com/machining-handbook/chapter-8/page/3
http://www.greenlinebicycles.com/manufacturingprocess.php
http://www.thefabricator.com/article/cuttingweldprep/how-to-perform-tackwelding-successfully
http://www.lucasmilhaupt.com/enUS/brazingfundamentals/properbrazingprocedure/
http://www.pedalinghistory.com/PHhistory.html
http://www.ilve.com.tr/proses.asp?d=ING&id=1
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