Presentation on

“ IN PLANT TRAINING AT
CANARA SPRINGS”
Presented By
Mr. AYMAN SHAIKH ANSAR 4BP15ME014

Guided by,
Prof. NITHIN S SALIAN
Department of Mechanical Engineering
Bearys Institute Of Technology, Mangalore.
 CONTENTS

• Introduction
• Details of Departments
• Manufacturing and Service Divisions
• Electrical Bay
• Express Bay
• Alignment Bay

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 INTRODUCTION
• The Company was established in the year 1943 by Late Mr. Vaman
Srinivas Kudva.
• CANARA SPRINGS produces leaf springs for all heavy commercial
vehicles, light commercial vehicles, passenger vehicles and also for
few passenger cars.
• The company is the first of its kind to start indigenous laminated
leaf spring manufacturing in India and also among the first to
introduce advanced technologies to improve the performance of leaf
springs.
• The company is spread over in the area of 23 acres of land with its
building for manufacturing activities occupying 2,80,000 sq.ft.

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 • MANUFACTURING AND SERVICE
DIVISIONS

– Steel melting

– Rolling mill

– Spring manufacturing

– logistics

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 Rolling mill

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 ROLLING MILL
• The 75 x 75 mm and 65 x 65 mm billets received from M/s.
Rashtriya Ispat Nigam Ltd., are cut into equal length of either
1.2 meter or 1.00meter depending on the cross section of flats
to be rolled.

• These cut billets are then loaded on to the billet re-heating

furnace and pushed into the furnace by mechanically operated
pusher.

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 • These billets travel through the furnace length and gets
heated up to a temperature of 1100°c Fully heated billets
are then ejected out at the discharge end by an ejector and
reach the finishing mill stands and passed through 14 passes
to get rolled into a required cross-section.

• From the final pass, the rolled flat is pushed by a

mechanized pusher into a stacking stand.

• We roll various cross section of flats ranging from 80 mm

to45 mm on the width and 15mm to 5 mm on the thickness

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 Spring Leaf Processing

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 Spring Leaf Finishing

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 Spring Processing

• Apart from springs steel flats rolled in our rolling mill, we also
procure flats from M/s. Marmagoa Steel Ltd, Goa, Jayaswal
Neco Industries, Raipur and Kontinental Steel Korporation,
Jharkand.

• These flats are delivered to springs division for further

processing.

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 Shearing

• The flats received and stacked are pushed through a flat

shearing machine and are cut to required lengths as per the
specifications provided.

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 Eye Rolling

• The main leaf or the top leaf of most of spring assemblies will
have a coil to facilitate fitment of assembly to the chassis.

• In order to provide this coil, the sheared leaves are heated at

the ends in an end heating furnace and processed through a
three stage eye rolling machine or hydraulic eye rolling
machine to form the coil of specified diameter at the ends.

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 Taper Rolling, Trimming & Hand Rolling

• This operation is carried out in a taper rolling machine mainly

for wrap around leaves (2nd leaf) which are then trimmed in
160 ton power press and hand rolled in a hand rolling
machine.

• These wrap around leaves are fitted below the main leaf and
circles around the main leaf coil.

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 Trimming & Bending

• In order to provide a trapezoidal shape at the ends of the

leaves, the sheared leaves are heated in an end heating
furnace and processed in 160 ton power press or 63 ton
power press where they get trimmed to specified shape.

• These trimmed leaves normally get fitted below the main leaf
or 2nd leaf in a spring assembly.

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 Diamond Trimming

• The shape of the ends of some of the leaves are trimmed to

form a shape resembling surface of a diamond, and hence the
name.

• This is carried out on a 40 ton power press.

• All the above operations are carried out after heating leaves in
a end heating furnace.

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 Nibbing/Buttoning

• This operation is carried out in a 40 ton mechanical press

where all the leaves including main leaves are heated at the
middle of the leaf formed into a button shape with the help of a
forging die.

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 Drilling

• This operation is to drill hole of specified diameter at the

centre or off centre depending on the specification of the part
number.

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 Heat Treatment
• The processed spring leaves are heated to a temperature of
825°c to 875°c in a conveyorised or walking beam furnace for
about 30 to 35 minutes depending on the cross section and
chemical analysis of the leaf.

• When it is discharged from the furnace, the leaves are

cambered to a desired bend in a cambering machine and
immediately dropped into a quenching tank filled with quench
oil.

• The leaves travel though the quenching medium for around 15

mts before being taken out.
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 • The trolley stacked with quenched leaves (hardened) are
moved into the tempering furnace chamber where they are
heated to a temperature of 450 degree C to 500 degree C and
remain in the chamber for 60 minutes after which the trolley is
pulled out and cooled.

• The heat treated leaves are verified for correct hardness in a

brinell hardness tester.

• These leaves are stacked in a trolley attached to a electrically

heated tempering furnace.

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 Rectification

• The heat treated leaves are subjected for minor camber

correction in a screw press to match the specimen leaves of the
same part number.

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 Shot Peening

• The heat treated and corrected leaves are passed through a shot
peening machine where the fine steel shots are hammered on
the top surface (tension surface) of the leaf at a high velocity.

• This operation improves fatigue life of spring leaves and also

better surface finish.

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 Bushing, Reaming & Grinding

• All the spring main leaves are inserted with mild steel bushes at both ends
by a hydraulic bush pressing machine.
• Inner diameter of the bush is reamed to clear any distortion created while
fitting the bush.
• Subsequently the sides of eyes are ground in an eye grinding machine to
enable the leaf to fit freely into the shackle of the vehicle chasis.
• Finally before the leaves are sent for painting and bundling, they are
checked for side bend and corrected in a hydraulic side bend correction
machine.

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 Assembly

• The company manufactures and supplies assemblies on specific order from

customers.

• For this purposed the required leaves are collected after shot peening. The camber
of these leaves are modified in a screw press for specific assembly camber.

• Clip leaves of the assembly are fitted clips and assembled along with the other
leaves in a hydraulic assembly table.

• These assemblies are subjected to scragging in a scragging machine where it is

deflected thrice in succession. This is to make the assembled leaves to set perfectly
without any gap between them.

• These assemblies are painted before dispatch.

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 Knowledge gained in Internship

• Industry work.
• Technical and innovative method of working.
• Knowledge about springs
• Working of different types of machines involved
• Assembling of leaf springs
• Quality control
• Facing the customers.

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