VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI –590018

An Internship Report
On
“MANUFACTURING OF SPRINGS”

Bachelor of Engineering
In
Mechanical Engineering
Submitted by

MOHAMED FAISAL
(4AD16ME039)

Internship Carried Out at

HINDUSTAN SPRINGS MANUFACTURING.CO

EXTERNAL GUIDE
INTERNAL GUIDE
Mrs. Dhaara
Mr. Pavan Kumar K P
Executive Manager
Assistant Professor
HSMC
Dept. of Mechanical Engineering
Mysuru
ATMECE, Mysuru.

DEPARTMENT OF MECHANICAL ENGINEERING

ATME College of Engineering,
Mysuru - Kanakapura Road,
Mysore - 570 028
Karnataka
Phone : +91-821-25 93 335
Website: www.atme.in
2019-20
 Department of
Mechanical Engineering

This is to certify that the Internship report titled “Hindustan Springs Manufacturing.Co”
carried out by Mohamed Faisal (4AD16ME039) in partial fulfilment of the requirements for the
(4
award of BACHELOR OF ENGINEERING in MECHANICAL ENGINEERING of
Visvesvaraya Technological University, Belgaum during the year 2019-2020.It is certified that all
corrections/suggestions indicated for internal assessment have been incorporated in the report. The
Internship report has been approved as it satisfies the academic requirements in respect of
internship work prescribed for the said degree.

Signature of Internal Guide

Mr. Pavan Kumar K P

Assistant Professor

Signature of HOD Signature of Principal

Dr. RATHNAKAR G Dr. L BASAVARAJ

External Examiners
Name of the examiners: Signature with date:

1.
2.
 DECLARATION

I, Mohamed Faisal USN: (4AD16ME017), student of “8th” semester B.E in Mechanical E

(
ATME College of Engineering, My
herebydeclare that entire work presented in
suru this
Internship Report submitted to the
VISVESVARAYA TECHNOLOGICAL UNIVERSITY
during the academic 2019-2020
year , is a record of an original work done
by me under the
guidance of InternalMr.Pavan Kumar K P, Assistant Professor,Department of
Guide -
Mechanical Engineering ATMECE, Mysuru and Mrs.Dhaara
External , GuideExecutive
- manager,
HSMC, Mysuru. This Internship work is submitted in partial fulfillment of
requirements for
the award of degree of of Engineering in Mechanical Engineering.
Bachelor It is
my original
work performed in company and it has not been submitted elsewhere
other award
degree.for any

Date: 15-8-2020 MOHAMED FAISAL

Place: Mysuru (4AD16ME039)
 ACKNOWLEDGEMENT

The constant encouragement of all sources has gone a long way in the accomplishment of the
Internship. I thank to all those who have rendered their cherished advices and services towards the
completion of the Internship.

I wish to express my deep sense of acknowledgement and gratitude to my Internal guide Mr.
Pavan Kumar K P, Assistant professor , Department Of Mechanical Engineering, for the suggestions
and encouragement throughout the making of the internship.
I wish to express my deep sense of acknowledgement and gratitude to my External guide Mrs.
Dhaara , Executive manager , HSMC, Mysuru, for the suggestions and encouragement throughout the
making of the internship.
I am highly indebted to Dr. Rathnakar G, Head of Department, Mechanical Engg, for his kind
consents and whole hearted cooperation

I would like to thank our Principal Dr. L Basavaraj, for his encouragement and providing an
excellent working environment.

I thank all the lecturers of the dept. for their cooperation and providing with the facilities to
carry out the seminar work. I would also express my thanks to all technical and non-technical staff of
mechanical engineering dept.,who have directly or indirectly cooperated with me.

Finally, I would like to express my gratitude to my parents and friends who always stood by me
encouraging in all my endeavors.

MOHAMED FAISAL
4AD16ME039
8th
Mechanical Engineering.
2019-20
 Executive Summary

Submitted by: CHIRANJEEVI N

Company Name: HINDUSTAN SPRINGS MANUFACTURING.CO

Work period covered: 39 Days Date submitted: 15/8/2020

 CONTENTS

CHAPTER 1: ABOUT THE COMPANY 1.

1.1 Introduction

CHAPTER 2: ABOUT THE DEPARTMENT 2.

2.1 Manufacturing Process

2.2 Coiling Process

CHAPTER 3: SECONDARY DEPARTMENT 4.

3.1 Extended hooks

3.2 loops and hooks

3.3 Swivel hooks

3.4 Torsion spring ends

CHAPTER 4: TORSION SPRING MANUFACTURING 7.

CHAPTER 5: GRINDING FOR COMPRESSION SPRINGS 7.
CHAPTER 6: STRESS RELIEF CHART 9.

CHAPTER 7: QUALITY CONTROL 11.

7.1 Quality policy

CHAPTER 8: FINISHING 12.

 8.1. Shipping/receiving

CHAPTER 9: SPRING MATERIAL PROPERTIES 13.

CHAPTER 10: OUTCOMES 14.

LIST OF FIGURES
Fig. No Caption Page no.

1.1 Company building 1

2.1 Manufacturing process 3

2.2 Coiling 3

3.1 Extended Hooks 4

3.2 Loops and hooks 5

3.3 Swivel Hooks 5

3.4 Torsion springs ends 6

5.1 Grinder 8

6.1 stress relief machine 9

7.1 Quality control 11

9.1 Spring properties 13

LIST OF TABLES

Table Caption Page no.

no.
6.2 Material properties 10
 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

CHAPTER 1: About the Company.

1.1. Introduction

Established in 1976, Hindustan spring Mfg.co. has immense expertise in supplying and
trading of springs, compression spring, tension spring etc. It is listed in Trade India’s list
of verified sellers offering supreme quality. It has a certification ISO 9001. The supplier
company is located in Mysore, Karnataka and is one of the leading sellers of listed
products. They sell springs, compression spring, and tension spring in bulk. This company
is one of the best quality product and service.They produce several types of springs based
on customer needs. This small scale industry employs semiautomatic and CNC machines.

Managing Partner: Mr. H.R Suryanarayana

Business type: Manufacture/supplier

Year Established: 1976

Number of Employess: 23

Total Annual Revenue: Rupees 2 crore

Fig 1.1

Dept. of Mechanical Engineering, ATMECE. Page 1

 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

CHAPTER 2: About the Department

2.1. Manufacturing Process

The spring manufacturing process starts with you, the customer. Once a Request for Quote
(RFQ) is received, along with a print or sample, we promptly work to provide a quote back
to you the same day, within a few hours in most cases. RFQs are first checked to see if we
can provide a part straight from our Stock Catalog.
Upon submitting a quote, we would point out any deviation at this point, examples being
wire size or finish. We may also make any design recommendations, to ensure a reliable
spring, as well.
Once you submit a PO, the CAD drawing and Specs are reviewed to ensure a good design.
All required tolerances, such as zinc plating are listed for manufacturing and then any POs
for outside processing are written up.
The order is then entered into our computer, an acknowledgement is generated back to the
customer, the internal order is then posted to stock raw material, we place an order for
material if needed. If material is available the order is sent to the shop to either go to the
coiling, handwork, or secondary department.

2.2. Coiling Process

This is the area where the automatic CNC coiling machinery operates. Automatic coilers
can handle wire from .008" to .625”.

Compression Springs are by far the most common type of spring. However Extension and
Torsion are also coiled via production machinery.

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Internship report – Hindustan Springs Manufacturing.Co 2019-2020

When dealing with large batch quantities, both mechanical and CNC machines are used
to coil the springs. The picture shows a view from the front of a mechanical coiler. The
link takes you to video of CNC machines.
The four large rollers on the front of the machine work in pairs and force the wire through
the wire guide towards the coiling point as shown in the picture on the right.
There are two grooved coiling points, one vertical and one horizontal from the right hand
side of the machine which are positioned round a half round mandrel. The four large
wire feeders force the wire through the coiling points which in turn force the wire round
the mandrel thus giving you the required spring coils.
The number of coils can be adjusted by the amount of wire feed. The pitch spacing and
the free length of the spring is governed by the spacing tool just visible on the right hand
picture at the twenty past position. When the spring coiling is completed, it is cut off by
the cutting tool.
Before this process can begin, tooling maybe required, mandrels may need ground, or
created to ensure proper bend radius.
For the smaller batch sizes and particularly when using thicker wire sizes, we use semi-
automatic CNC or a lathe.

Fig 2.1

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Internship report – Hindustan Springs Manufacturing.Co 2019-2020

Fig 2.2
CHAPTER 3: Secondary Department

Wire forms: Wire forms are any shape made out of wire — not just a coil. There are a
jillion different kinds of wire forms.
Limited-travel extension springs: Sometimes you'll want to make an extension spring that
only extends so far and then stops. You'll see these sometimes on screen doors, or farm
fencing, these are called draw bar springs.

3.1. Extended Hooks

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 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

Fig 3.1

You may want to make an extension spring with extended hooks, like this
The best way to do this is to coil the spring as if it were a torsion spring and then bend the
ends over to form the extended hooks.

3.2. Loops and Hooks

Fig 3.2

Loops will work best for most extension springs. Sometimes, though, you'll want hooks —
like when you'll want to slip the spring onto a pin, for instance.
Making hooks is very simple, once you've made loops: all you have to do is cut the end of
the wire off so that it doesn't come all the way around to the body of the spring.

Dept. of Mechanical Engineering, ATMECE. Page 5

 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

3.3. Swivel Hooks

Fig 3.3

Extension springs are also sometimes made with hooks that are separate from the spring
that swivel. The last few end coils would be a conical shape to hold the hook in place.

3.4. Torsion Spring Ends

Fig 3.4

Don't forget that torsion springs come left-handed and right-handed. Be sure to make you
request the correct direction.
Torsion Springs start with straight arms. They quite often have one or more bends, to fit
within a movement device, tooling, or to hit a stopping point in the final product.
Double torsion springs: You recall how torsion springs can be either left-handed or right-
handed? Well, sometimes you'll want to make a torsion spring that's both. Such springs are
sometimes found on clipboards, and they might look like this.

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 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

Making double torsion springs means making some pretty specialized tooling, Depending
on the wire size, they can be formed on a CNC machine or a manual lathe treatment, since
the setup time is minimal, the springs can be produced more economically.

CHAPTER 4: Torsion Spring Manufacturing

The secondary department is where small quantities of wire are bent by hand. Once the
spring is coiled, this is where the ends of torsion springs are formed, where loops are
put onto the ends of extension springs, and where wire forms are made.

CHAPTER 5: Grinding For Compression Springs

A common requirement for compression springs is to grind the ends flat. In the
majority of cases this grinding flat of the ends is done on an automatic grinding
machine. These machines consist of a round plate into which ushing are fitted. The
bushing inside diameter is of a size so that the springs will fit leaving a small amount
of spring protruding top and bottom. The plate then turns slowly round so that the
bushing plus springs pass in between either one pair of grinding wheels or as in the
illustrated photograph, two pairs of grinding wheels depending on what type of
machine is used.
The grinding wheels grind the ends of the springs flat and square and then they drop
into a waiting box for inspection when they are thoroughly tested to make sure they
comply both dimensionally and in their load requirements.
If you're looking at the end of the spring, the ground surface should look like the
graphic, once ground.

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 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

Fig 5.1

The other thing to check is how square your ground ends are. You can do this by setting
your spring down next to a carpenter's square, a machinist's square, a book, or anything
else that stands up straight. Then, holding the bottom end of the spring next to your square,
turn the spring around and watch the gap between the square and the top end.
If your spring is perfectly square, there will be no gap as you turn the spring around. A
small gap is OK, since the ends of the spring will flatten out under load (Commercial
squareness in spring shops is ±3 degrees). Generally 3/4 of the bearing surface is ground
and 1/2 of the wire thickness is ground off. This is the department where the ends of
compression springs are ground. A lot of the work is done with automatic machines,
which pass the springs between two large grinding wheels so that both sides of the spring
can be ground at once.

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Internship report – Hindustan Springs Manufacturing.Co 2019-2020

CHAPTER 6: Stress Relief Chart

Spring wire that gets shaped has to have the bending stress relieved in the form of heat
treating. Various wire materials require different lengths of time for stress relief.
The process of baking out the stress in the wire may change the dimensions of your
spring. Stainless steel coils will generally expand slightly when heated: music wire coils
will generally contract slightly.

(a)

(b)

(c)

Fig 6.1 (a,b,c)

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Internship report – Hindustan Springs Manufacturing.Co 2019-2020

CHART 6.2
MATERIAL OUTER DIAMETER (OPENS/ TEMPERATURE TIME
CLOSES)

Hard Drawn Closes 550 F 20 mins

K Monel 1000 F 4 hours

Monel not move 600 F 1 hours

Valve Oil Tempered Closes 600 F mins or until blue on

ends

Oil Tempered Closes 500 F - 600 F 30 mins

Music Wire Closes 500 F 30 mins

Stainless Steel 302 Opens 600 F - 650 F 30 mins

Stainless Steel 316 does not move 700 F 1 hour

Stainless Steel 17-7PH or opens a little 900 F 1 hour

17-4PH

Inconel 718 1375 F 16 hours

Inconel 700 F - 900 F 1 hour

Inconel No. 1 Temper does not move 1375 F 16 hours then reduce
to 700 F for 1 hour

Inconel X-750 1225 F 4 hours

Inconel 600 900 F 1 hour

Inconel X Spring Temper 1250 F 4 hours

Chrome Silicone Closes 800 F 30 mins

Chrome Vanadium Closes 800 F 30 mins

Bronze 350 F 15 mins

Beryllium Copper closes 1% 600 F 30 mins to 2 hours

Beryllium Copper 25 1/2 600 F 30 mins

hard

Elgiloy (open more in salt) opens 3% 900 F 5 hours

Aluminum 400 F 30 mins

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 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

Brass just warm up just warm up

Basic none None

Premier 600 F - 650 F 15 to 30 mins

Rene 41 1400 F 16 hours

Ni Span C (on big wire) opens some 1250 F 3 hours

Ni Span C Alloy 902 50% 900 F 5 hours

cold worked

Titanium opens (like SS) 800 F 10 hours

Maraging Flat Stock does not move 950 F 4 hours NO LESS

Maraging Wire does not move 850 F 30 mins

MP35N 1200 F 4 hours

Hastelloy C-22 Stress Relief @ 750 F-840 F 30 mins

Rocket Wire Min. Tensile 525 F 2 hours

Strength 25 KS

CHAPTER 7: Quality Control

Checks tolerance to ensure your springs were manufactured to your specifications.

Tolerances generally held to S.M.I. commercial standards and not to a machinist block.

Springs are specifically designed to be resilient, even when going through vigorous
deflections. A key component to this resiliency is in the spring material. The choice of
material is based on numerous factors ranging from fatigue strength.

Fig 7.1

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 Internship report – Hindustan Springs Manufacturing.Co 2019-2020

7.1. Quality Policy

Diamond Wire Spring Company is committed to customer focus and customer confidence
by providing products and customer service that fulfill customer requirements. To achieve
these objectives, Diamond Wire Spring Company will continually improve the
effectiveness of our Qualtiy Management System.

CHAPTER 8: Finishing

This section will tell you about a few of the finishing touches you can put on your springs.
Some of these are necessary, while others may be called for by the design you have in
mind.
We can paint your springs or add a color code stripe, in any color on our paint line.
eCoating, Powder coating, Passivating, Plating, Electro polishing, or Magna flux are all
examples of types of coatings added to springs, mostly as an environmental protection.

8.1. Shipping / Receiving

Before your springs are shipped we package them in bags, boxes, drums, or pallets all
dependent upon the lot size. We can handle customer release schedules to incude JIT,
Kanban, and Blanket orders.
We can custom label each package or each part. We will ship using which ever freight
carrier the customer requests.

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CHAPTER 9: Spring Material Properties

Springs are specifically designed to be resilient, even when going through vigorous
deflections. A key component to this resiliency is in the spring material. The choice of
material is based on numerous factors ranging from fatigue strength, cost and availability,
corrosion resistance, magnetic permeability and even electrical conductivity.

Fig 9.1

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Internship report – Hindustan Springs Manufacturing.Co 2019-2020

CHAPTER 10: Outcomes

During my internship experience with Universal Automobile and Dairy Products, I got to
know how springs are manufactured in a small scale industry.

Springs are the vital components of machines, for manufacturing these small components
it involves many different processes.

During this internship I was able to develop my active listening skills. I particularly found
direct interactions with these workers to be useful in improving my knowledge about
springs.

I believe they were valuable in developing my confidence as a mechanical engineer.

Dept. of Mechanical Engineering, ATMECE. Page 14