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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELAGAVI - 590 018, KARNATAKA

An Internship Report on

Extrusion Of Aluminium Submitted in partial fulfilment of the requirements for the degree of

Bachelor of Engineering in

MECHANICAL ENGINEERING (VISVESVARAYA TECHNOLOGICAL UNIVERSITY , BELAGAVI) BY Madhushree K 4MT16me064 Internship carried out at Bhoruka Extrusion Pvt Ltd , Mysore Internal Guide Mr. Gowtham Shetty Assistant Professor MITE, Moodabidri

External Guide Mr. Pradeep Rajshekar HR Manager Bhoruka Extrusion Pvt Ltd

DEPARTMENT OF MECHANICAL ENGINEERING

(UG PROGRAMME ACCREDITED BY NBA, NEW DELHI)

MANGALORE INSTITUTE OF TECHNOLOGY AND ENGINEERING Mijar, Moodabidri– 574225

MANGALORE INSTITUTE OF TECHNOLOGY AND ENGINEERING Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

(Affiliated to Visvesvaraya Technological University, Belagavi)

Mijar, Moodabidri – 574225

Department of Mechanical Engineering

(UG programme accredited by NBA, New Delhi)

CERTIFICATE Certified that the Internship work entitled “Extrusion Of Aluminium” was carried out at Bhoruka Extrusions Pvt Ltd, Mysore by Madhushree K,USN: 4MT16ME064, is a bonafide student of VIII semester B.E, Mechanical Engineering Department of Mangalore Institute of Technology and Engineering, Moodabidri-574225, in partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya Technological University, Belagavi during the academic year 2020-21. It is certified that all corrections/suggestions indicated by the guide have been incorporated in the report. The internship report has been approved as it satisfies the academic requirements in respect of the internship prescribed for the said degree.

Mr.Gowtham Shetty Internal Guide

Dr. C R Rajashekar

Dept. of MechanicalEngineering

Head of the Department

Dept. of MechanicalEngineering

Dr G L Easwara Prasad Principal

EXTERNAL VIVA VOCE EXAMINATION 1. Name : Designation:

Signature with date

2. Name:

Designation:

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

Signature with date

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

DECLARATION I hereby declare that the Internship report entitled, 'Extrusion Of Aluminum' which is being submitted to the Visvesvaraya Technological University, Belagavi, 590018, Karnataka in partial fulfilment of the requirement for the award of the degree of Bachelor of Engineering in Mechanical Engineering, carried out at Mangalore Institute of Technology and Engineering, Moodabidri 574225, is a bonafide report of the work done by me. The material contained in this report has not been submitted to any university or Institution for the award of any degree.

Name of the student: Madhushree K USN of the student: 4MT16ME064 Signature of the student : Place: Moodbidri Date:

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

EXECUTIVE SUMMARY Every student of Bachelor of Technology in Mechanical Engineering , has an essential requirement to do internship in any of well reputed organization.The purpose of this program is to acquaint the student with practical application of theoretical concepts taught to them during conduct of their course. It was a wonderful learning experience at BHORUKA EXTRUSION PRIVATE LIMITED for a month in Mysore. I gained a lot of insight regarding almost every aspect of plant. The friendly welcome from all the employees is appreciating, sharing their experience and giving their peace of wisdom which they have gained in long journey of work. It was a nice opportunity to have theoretical concept in practical field. In the plant we learned about extrusion of aluminum metal into different designs for different uses. Here I gained the knowledge about extrusion, billet casting, die casting, anodizing , powder casting. The output of my analysis is summerizedin a shape of internship the contents of the report ,shows the detail of sequence of these.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

ACKNOWLEDGEMENT I, Madhushree K express my deep gratitude to Mr. Rajesh Chouta, Chairman for providing all the facilities for the timely completion of the internship. Iam indebted to our respected Principal, Dr G L Easwara Prasad for having provided all the facilities and support for the smooth completion of the internship. I am grateful to Dr. C R Rajashekar, Head, Department of Mechanical Engineering, for his support and encouragement. I would like to offer my earnest gratitude to our External Guide, Mr Pradeep Rajshekar, HR Manager, Bhoruka Extrusion Pvt. Ltd and my Internal guide, Gowtham Shetty , Assistant Professor, Department of Mechanical Engineering, MITE, Moodabidri. This work would not have been possible without their guidance and support. I wish to express my sincere gratitude to all the Faculty and Technical staff of the Department of Mechanical Engineering, MITE, Moodabidri, for their valuable help and support.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Content  Executive Summary …………………………………………………………..  Acknowledgement …………………………………………………………….

4 5

 Chapter 1 : Company Profile 1.1 General Introduction ……………………………………………… . 1.2 Vision ………………………………………………………………... 1.3 Objective ……………………………………………………………... 1.4 Organization Chart ………………………………………………….. 1.5 Application approved ……………………………………………….. 1.6 Certification………………………………………………………… .. 1.7 BEPL clients a customer ……………………………………………..

9 10 10 10 11 12 13

 Chapter 2 : Task Performed 2.1 Work Flow Chart ………………………………………………… 14 2.2 Raw Material 2.2.1 Extraction Of Aluminum …………………………………. 2.2.2 Foundry Department ……………………………………… 2.2.2.1 Fuel Usage …………………………………………. 2.2.2.2 Furnace ……….……………………… 2.2.2.3 Billet Casting ……………………………………...

15 15 15 16 17

2.3 Extrusion 2.3.1 Types Of Extrusion ………………………………………… 2.3.2 Direct Extrusion ……………………………………………. 2.3.3 Hot Extrusion... ……………………………………………. 2.3.4 Cold Extrusion ……………………………………………… 2.3.5 Extrusion Dies ……………………………………………… 2.3.6 BEPL Products ………………………………………………

18 19 20 21 21 22

2.4 Anodizing 2.4.1 Process ………………………………………………………

23

2.5 Powder Coating 2.5.1 Advantages Of Powder Coating ……………………………. 27 2.5.2 Types Of Powder Coating …………….……………………….28 2.5.3 Pre-process ; Part preparation & Equipment …………………. 28 2.5.4 Powder Application Process …………………………………. 29 2.5.5 Other Methods Of Coating …………………………………... 30

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.6 Nitrding 2.6.1 Process ……………………………………………………… 31 2.6.1.1 Gas Nitriding ……………………………………….. 31 2.6.1.2 Salt Bath Nitriding …………………………………. 32 2.7 Shot Blasting …………………………………………………………… 34 2.8 Tool Room Department ………………………………………………

34

2.9 Fabrication ……………………………………………………….. ….

34

2.10 System Housing ……………………………………………………..

35

2.11 Maitainance ……………………………………………………… …

36

 Chapter 3 : Result Analysis

3.1 Extrusion 3.1.1 Advantages Of Extrusion …………………………………. 37 3.1.2 Disadvantages Of Extrusion …….………………………… 37 3.1.3 Application Of Extrusion ………………………………….. 38 3.2 Anodizing 3.2.1 Advantages Of Anodizing ……………………………………. 38 3.2.2 Disadvantages Of Anodizing ……….…………………………. 40 3.2.3 Application Of Anodizing …………………………………….. 40 3.3 Powder Coating 3.3.1 Advantages Of P.C ……………………………………………. 40 3.3.2 Disadvantages Of P.C ………………………………………… 40 3.3.3 Applications Of P.C …………………………………………… 41 3.4 Nitriding 3.4.1 Advantages Of Nitriding ………………………………………… 41 3.4.2 Disadvantages Of Nitriding ……………………………………... 41  Chapter 4 : Conclusion ………………………………………………………… 42  Chapter 5 : Certificate Of Internship…………………………………………… 43  Chapter 6 : Bibliography ……………………………………………………….. 44

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

List Of Table Table 1 : Organization Chart ……………………………………………………………… 11 Table 2: Technical Sheet ………………………………………………………………… 18 Table 3 : Hot extrusion temperature ……………………………………………………… 20 Table 4 : Die Design Parameters …………………………………………………………. 21

List Of Figures 1. 2. 3. 4. 5. 6. 7. 8. 9.

Bhoruka Logo ……………………………………………………………………………9 BEPL Mysore Unit……………………………………………………………………....9 Application Approved…………………………………………………………………...11 IGBC certification……………………………………………………………………….12 ISO certification………………………………………………………………………....12 Griha Certification……………………………………………………………………….12 Clients & Customers……………………………………………………………………..13 Flow Chart……………………………………………………………………………….14 a . Melting metal in Crucible for casting………………………………………………...15 b. Furnance………………………………………………………………………………17 10. Billets……………………………………………………………………………………15 11. Direct Extrusion………………………………………………………………………....17 12. Hot Extrusion…………………………………………………………………………....20 13. Cold Extrusion………………………………………………………………………...…21 14. Die pattern…………………………………………………………………………..…...22 15. BEPL Product……………………………………………………………………. …….22 16. Anodizing Product………………………………………………………………..….…..23 17. Powder Coating spray gun…………………………………………………….…………29 18. Powder coated aluminum ……………………………………………………………….29 19. Salt bath nitriding………………………………………………………………………..32

List Of Abbreviation  BEPL – Bhoruka Extrusion Pvt Ltd  P.C – Powder Coating

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

CHAPTER 1 : COMPANY PROFILE 1.1 GENERAL INTRODUCTION Established in 1979, Bhoruka Extrusions Private limited (Formerly known as Bhoruka Facades Private Limited) deals in a wide range of products that cater to customers throughout the globe. It is continually striving to become the undisputed leader in aluminium extrusion From 1st June 2013, it have become a wholly owned subsidiary of YKK Group, Singapore. At Bhoruka, quality has always been a hallmark. All work processes are subjected to highest quality checks to eliminate anything that is below outstanding. Their target is total client satisfaction along with delivery schedules that are always on dot. Excellence being our aim, we have an unflinching commitment towards development, and ensure constant improvisation of our products and services. By being the only 100% made to order extruder in India with a capacity of 1500 MT / month, and with a strong product base, we are uniquely positioned to cater to your every desire. The Modern plant is equipped with an automatic PLC (programmable logic controller ) controlled 1650MT , wean united and a compact 980 MT years change make oil hydraulic extrusion process with flexibility to extrude 5.5 , 6 and 7 diameter millet. Both the presses have close controls on the speed and a high degree of stability.

Fig 1

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

fig 2

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

1.1.1 Company Details : Company Name : BHORUKA EXTRUSION PVT LTD Address

: No 1, KSR Road, Metagalli, Mysore – 570016 , Karnataka,India

Email

: [email protected]

Fax

:+91-821-4286112

Phone

:+91-821-4286100

1.1.2 BEPL Fact :          

Wholly owned subsidiary of $7 Billion YKK Group, Japan Extrusion capacity of 1000 MT / Month (6”/ 8”/ 9” - extrusion press) In-house Anodizing capacity of 250 MT / Month (Italtechno, Italy) In-house Powder coating capacity of 350 MT / Month (Nordson , U.S.) Approved PE-F/D-1036 and PE-SDF/D-2525 Applicator Award winning SAP implementation ( ECC 6.0) Approved extruder of systems –Airclos, Alu-K, Asahi, Dorma, EFP, IWIN-S, Lixil, Reynaers, Schueco Online self-updating E-catalogue ( www.bhorukaecatalogue.com) Online order tracking through SAP (Bhoruka 360 CRM portal) and Planning ( E-Planner) Branches: Bangalore, Chennai, Coimbatore, Delhi, Hyderabad, Mumbai, Mysore, Pune

1.2 : VISION “To be the preferred provider of aluminium extrusions to our customers by becoming an industry leader” 1.3 : OBJECTIVE          

To meet the requirements of external and internal customers on sustained basis To understand and fulfill functional requirements of the customer To incessantly supply material as per delivery schedule To instigate and maintain a highly skilled, motivated and disciplined team To ensure quality in die design and manufacturing. To minimize dependence on Inspection To achieve high productivity and minimum handling To improve the capabilities of vendors by engaging in continuous dialogue and feedback To minimize cost by reducing wastes, re-work and scrap To ensure cleanliness and good housekeeping

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

1.4 : Organization Chart : Designation

Name

Managing Director

Mr. Fumihiko Umano

Technical Director

Mr. Akira Miyazaki

Sales Director

Mr. Rajat Agarwal

Factory Manager

Mr. Prasanna Venkatesh

Planning

Ms. Suma S

Extrusion

Mr. Vijay N

Quality Control

Mr. Veerendra Rudresh

Coating

Mr. Prashanth C

Joshi Finance

Mr. Jenil Ramesh

HR

Mr. Pradeep Rajshekar

Table 1 1.5 Approved Applications – Akzo & Jotun

Fig 3

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

1.6 Certifications :

Fig 4

Fig 5

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

Fig 6

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

1.7 BEPL Clients And Customer :

Fig 7

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

CHAPTER 2 : TASK PERFORMED 2.1 : Work Flow Chart

Fig 8 Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.2 Raw Materials : The life cycle of our extruded products begins at the raw material stage, where we use only premium quality aluminium ingots to ensure reliability.The aluminium ingots are then melted and cast into billets of the required size. The billets are then heated to the optimum temperature and fed into any one of our three presses according to the client’s requirements. The extruded aluminium is then cooled according to specification and it is to be noted that BEPL enforces strict quality regulations at each step of the production process.BEPL houses an advanced tool shop that is capable of producing and designing very intricate die setups. The tool shop has continually proved its capability to handle even the most complicated dies. 2.2.1 : Extraction of Aluminium :  

Bauxite , the main ore of aluminum which contains Aluminium oxide Aluminium is made by electrolysis of aluminium oxide

2.2.2 : Foundary department A foundry is a factory that produces metalcastings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.  Process 1. Melting

Fig 9.a Melting metal in a crucible for casting

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2. A metal die casting robot in an industrial foundry Melting is performed in a furnace.Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and other extraneous metal oddments produced within the facility. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refiningis done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made. 2.2.2.1: Fuel Usage : Coal , furnance oil and electricity are primary energy input in aluminium production..Coal is the primarily used to generate steam, which is in the process while fuel oil mainly used in calcinations of alumina various furnance in the fabrication plants. 2.2.2.2 : Furnace Furnace is where aluminum ingots or aluminum materials are melted down and molded into finished or semi-finished products by molten casting . Several specialized furnaces are used to heat the metal. Furnaces are refractory-lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include  electric arc furnace(EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces. Furnace choice is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to the type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 °C (932 °F). Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel-based alloys, the furnace must be designed for temperatures over 1,600 °C (2,910 °F). The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces) or coke. The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.2.3: Billet cutting A billet is a section of metal used for rolling into bars, rods and sections. It can be produced with ingots or directly by continuous casting. Billets are used as raw materials or extrusion processing operations.

Fig 9 .b

Fig 10

2.3 : Extrusion : Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed a die of the desired cross-section. Extrusion may be continuous ( theoretically producing in definitely long material ) or semicontinuous (producing many pieces). The extrusion process can be done with the material hot or cold .commonly extrude ,materials includes metals ,polymer ceramics , concrete ,modeling clay and foodstuffs. The products of extrusion are generally called “ extrudates ” . Bhoruka extrusion modern plant is equipped with an automatic PLC controlled 2750MT Cheng Hua press, 1650MT Wean United and a compact 980MT year Chang make oil hydraulic extrusion press with flexibility to extrude 6’’ ,7’’, 8’’ and 9’’dia billet. All presses have close controls on the speed and a high degree of stability. They are supported by hot log shear from Granco Clark USA,,automatic puller and handling systems, producing extrusions. The process begins by heating the stock material (for hot or warm extrusion). It is then loaded into the container in the press. A dummy block is placed behind it where the ram then presses on the material to push it out of the die. Afterward the extrusion is stretched in order to straighten it. If better properties are required then it may be heat treated or cold worked. Extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. One of the main advantage of the extrusion process is that this ratio can be very large while still producing quality. Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Table 2 Parameter

Press 1

Press 2

Press 3

Make

Wean united(USA)

Year Chang (Taiwan)

Cheng Hua (Taiwan)

Strength of

1800

960

2750

Diameter of billet

203mm

152mm

228mm & 203mm

Diameter of

210mm

158mm

236mm & 210mm

37

25

44.48

9

7.087

9.09

3000psi

3000psi

3335psi

Mark of Billets

6063 ,6005

6063 ,6005

6063, 6060, 6101, 6005

(6063-6060)

6105, 6061

6105 ,6061

6351,6061,6082

Conveyor length

36Mtrs

36Mtrs

50.90Mtrs

Type of billet oven

Hot long shear

Induction

Hot long shear

Track type

Track type

Track type

Extrusion press (tons)

Container Diameter of main Cylinder- inches Diameter of small Cylinder- inches Maximum pressure of Press (BAR)

(Gas,diesel,induction) Type of puller

2.3.1 : Types Of Extrusion:    

Direct Extrusion Indirect Extrusion Impact Extrusion Hydrostatic Extrusion

In BEPL , Direct Extrusion Method is used for Extrusion of aluminium.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.3.2 : Direct Extrusion Direct extrusion, also called forward extrusion, is a process in which is the billet moves along the same direction as the ram and punch do. Sliding of billet is against stationary container wall.Friction between the container and billet is high. As a result, greater forces are required. A dummy block of slightly lower diameter than the billet diameter is used in order to prevent oxidation of the billet in hot extrusion. Hollow sections like tubes can be extruded by direct method, by using hollow billet and a mandrel attached to the dummy block.

Fig 11

Extrusion force, which is the force required for extrusion, in direct extrusion, varies with ram travel as shown in figure above. Initially the billet gets compressed to the size of container, before getting extruded. Also, initially static friction exists between billet and container. As a result the extrusion pressure or force increases steeply as shown. Once the billet starts getting extruded, it length inside the container is reduced. Friction between billet and container now starts reducing. Therefore, extrusion pressure reduces. The highest pressure at which extrusion starts is called breakthrough pressure. At the end of the extrusion, the small amount of material left in the container gets pulled into the die, making the billet hollow at centre. This is called pipe. Beyond pipe formation, the extrusion pressure rapidly increases, as the small size billet present offers higher resistance. As the length of the billet is increased, the corresponding extrusion pressure is also higher because of friction between container and billet. Therefore, billet lengths beyond 5 times the diameter are not preferred in direct extrusion. Direct extrusion can be employed for extruding solid circular or noncircular sections, hollow sections such as tubes or cups.  Types Of Direct Extrusion:  Hot Extrusion  Cold Extrusion

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.3.3 : Hot Extrusion : Hot extrusion is a hot working process, which means it is done above the material's recrystallization temperature to keep the material from work hardening and to make it easier to push the material through the die. Most hot extrusions are done on horizontal hydraulic presses that range from 230 to 11,000 metric tons (250 to 12,130 short tons). Pressures range from 30 to 700 MPa (4.400 to 101.500 s), therefore lubrication is required, which can be oil or graphite for lower temperature extrusion, or glass powder for higher temperature extrusions. The biggest disadvantage of this process is its cost for machinery and its upkeep. The extrusion process is generally economical when producing between several kilograms (pounds) and many tons, depending on the material being extruded. There is a crossover point where roll forming becomes more economical. For instance, some steels become more economical to roll if producing more than20,000 kg (50,000 lb) .

Fig 12  Hot extrusion temperature for various metals :

Materials

Temperature (ºc [ºF])

Magnesium

350-450[650-850]

Aluminum

350-500[650-900]

Copper

600-1100[1200-2000]

Steel

1200-1300[2200-2400]

Titanium

700-1200[1300-2100]

Nickel

1000-1200[1900-2000]

Refractory alloys

Up to 2000[4000]

Table 3

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.3.4 : Cold Extrusion: Cold extrusion is done at room temperature or near room temperature. The advantages of this over hot extrusion are the lack of oxidation, higher strength due to cold working, closer tolerances, better surface finish, and fast extrusion speeds if the material is subject to hot shortness. Materials that are Commonly used in cold extrusion process include: lead, tin, aluminum, copper, zirconium, titanium, molybdenum, beryllium, vanadium, niobium, and steel. Examples of products produced by this process are: collapsible tubes, fire extinguisher cases, shock absorber cylinders and gear blanks. Recrystallization temperature of the material the temperature ranges from 800 to1800 °F (424 to 975 °C). It is usually used to achieve the proper balance of required forces, ductility and final extrusion properties and shear stresses. It also forms parts with an excellent surface finish.

Fig 13 2.3.5 : Extrusion Dies: Die types

Solid, Hollow

Diameter CCD

Solid – 254mm; Hollow-230mm

Number of sections

More than 10000

Time taken for die development

Solid – 15 days; Hollow – 21 days Table 4

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Fig 14

2.3.6 : BEPL Products :

Fig 15

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.4: Anodizing: Anodizing (spelled anodizing in British English) is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts. The process is called anodizing because the part to be treated form the anode electrode of an electrical circuit. Anodizing increases resistance to corrosion and wear, and provides better adhesion for paint primers and glues than bare metal does. Anodic films can also be used for a number of cosmetic effects, either with thick porous coatings that can absorb dyes or with thin transparent coatings that add interference effects to reflected light. Anodizing is also used to prevent galling of threaded components and to make dielectric films for electrolytic capacitors . anodic films are most commonly applied to protect aluminum alloys , although processes also exist for titanium, zinc ,magnesium, niobium ,zirconium, hafnium ,and tantalum. Iron or carbon steel metal exfoliates when oxidized under neutral or alkaline micro electrolytic condition i.e. the iron oxide ( actually ferric hydroxide or hydrated iron oxide also known as rust) forms by anoxic anodic pits and large cathodic surface , these pits concentrate anions such as sulphate and chloride accelerating the underlying metal to corrosion . carbon flakes or nodules in iron or steel with high carbon content may caused an electrolytic potential and interface with coating or plating. Ferrous metals commonly anodized electrolytically in nitric acid or by treatment with red fuming nitric acid to form hard black ferric oxide Anodizing changes the microscopic texture of the surface and the crystal structure of the metal near the surface. Thick coatings are normally porous, so a sealing process is often needed to achieve corrosion resistance. Anodized aluminium surfaces, for example, are harder than aluminium but have low to moderate wear resistance that can be improved with increasing thickness or by applying suitable sealing substances. Anodic films are generally much strong rand more adherent than most types of paint and metal plating, but also more brittle. This makes them less likely to crack and peel from aging ad wear but more susceptible to cracking from thermal stress. A modernized, PLC controlled anodizing / electro coloring plant from Ital techno, Italy ensures uniform coating to match the taste & decor for varied applications, without any color variation. The extrusions are anodized up to 25 micron in different color like silver, champagne, bronze and black. A full proof sealing system ensure durable finish for long lasting applications.

2.4.1:Process The anodized aluminium layer is grown by passing a direct current through an electrolytic solution, with the aluminium object serving as the anode (the positive electrode)." The current releases hydrogen at the cathode (the negative electrode) and oxygen at the surface of aluminum anode creating a build-up of aluminum oxide. Alternating current and pulsed current is also possible but rarely used. The voltage required by various solutions may range from 1 to 300 v DC, although most fall in the range of 15 to 21 V. Higher voltages are typically required for thicker coatings formed in sulphuric and organic acid. The anodizing current varies with the area of aluminium being anodized and typically ranges from 30 to 300 A/m (2.8 to 28 A/f). Aluminium anodizing is usually performed in an acid solution, which slowly dissolves the aluminium oxide. The acid action is balanced with the oxidation rate to form a coating with Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

nonporous, 10-150 nm in diameter. These pores are what allow the electrolyte solution and current to the aluminium substrate and continue growing the coating to greater thickness beyond what is produced by auto passivation. However, these same pores will later permit air or water to reach the substrate and initiate corrosion if not sealed. They are often filled with colored dyes and/or corrosion inhibitors before sealing. Because the dye is only superficial, the underlying oxide may continue to provide corrosion protection eve n if minor wear and scratches may break through the dyed layer. Conditions such as electrolyte concentration acidity, solution temperature and current must be controlled to allow the formation of a consistent oxide layer .Harder, thicker films tend to be produced by more dilute solutions at lower temperatures with higher voltages and currents. The film thickness can range from under 0.5 micrometers for bright decorative work up to 150 micrometers for architectural applications. The bhoruka extrusions include different tanks for the anodizing process. 

Degreasing tank  Concentration-35-60g/1  Temp: 50-68 c  Clenol chemical is used

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Etching  Concentration-55-95g/  Temp-50-70c  Casting soda  For washing h2so4+DF water is used

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Colouring tank  Different colours with codes BSM, BLH, BMB, BDB, BLK  TIME: up to 15 min

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Spare coloring tank for light pink.

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Cold steel tank  Concet-3-8g/1  Ph: 5.50-7.00, dipping time: Imin/micron

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Hot seal  Temp-90-100c.  Ph: 5.5-700, dipping time: Imin/micron

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The cooling of the product at the end in this process is done with room temperature

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

 There are several benefits to getting you products anodized  

  

Anodizing is corrosion resistant -The Aluminium Oxide coating is very resistantto chemical attack, and is only really affected by strong acids or alkalis Anodizing is wear & scratch resistant -The anodised layer is much harder than the Aluminium substrate underneath. Aluminium oxide is in itself a very hard substance, it measures 9 on the Moh scale of hardness (diamond is 10 on Moh scale). Aluminium oxide is used as an abrasive product in sand papers due to its hardness . Anodizing won't peel or flake -The anodised layer is a part of the Aluminium and its ,normal separate layer like powder coating or paint. Anodizing is easy to clean – All it takes is soap and water ,but avoid extreme abrasive. Finger prints don’t show- now there is a bonus.

Fig 16

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.5 :Powder coating: Powder coating is a type of coating that is applied as a free-flowing, dry powder . The main difference between a conventional Iiquid paint and a powder coating is that the powder coating does not require a solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically applied electro statically and is then cured under heat to allow it to flow and form a "skin". The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint .Powder coating is mainly used for coating of metals, such as household appliances, aluminium extrusions, and automobile and bicycle parts. Newer technology allow other materials, such as MDF (medium-density fibre board),to be powder coating using different method. Because powder coating does not have a liquid carrier, it can produce thicker coatings than conventional liquid coatings without running or sagging, and powder coating produces minimal appearance differences between horizontally coated surfaces and vertically coated surfaces. Because no car carrier fluid evaporates away, the coating process emits few (VOC). Finally, several powder colors can be applied before curing them all together, allowing colour blending and bleed special effects in a single layer. While it is relatively easy to apply thick coatings which cure to smooth, texture .free coating, it is not as easy to apply smooth thin films. As the film thickness is reduced, the film becomes more and more orange peeled in texture due to the particle size and glass transition temperature (Tg) of the powder. .Most powder coatings have a particle size in the range of2 to 50 (Microns),a softening temperature Tg around 80 °C, a melting temperature around 150 °C, and are cured at around 200 °C. For minimum 10 minutes to 15 minutes (exact temperatures and times may depend on the thickness of the item being coated). For such powder coatings, film build-ups of greater than 50(Microns) may be required to obtain an acceptably smooth film. The surface texture which is considered desirable or acceptable depends on the end product. Many manufacturers actually prefer to have a certain degree of orange peel since it helps to hide metal defects that have occurred during manufacture, and the resulting coating is less prone to showing fingerprints. Aluminium extrusions being powder coated There are very specialized operations where powder coatings of less than 30micrometres or with a Tg below 40 °C are used in order to produce smooth thin films. One variation of the dry powder coating process, the Powder Slurry Process, combines the advantages of older coating and liquid captain by dispersing very fine powders of 1-5 micrometers partical size into water ,which then allows very smooth ,low film thickness captain to be produced. For garage-scale jobs, small "rattle can” complex than powder coating, At the professional scale, the capital expense and time required for a powder coat gun, booth and oven are similar to a spray gun system. Powder coatings have a major advantage in that the overspray can be recycled. However, if multiple colours are being sprayed in a single spray booth, this may limit the ability to recycle the overspray. Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]



Impression of colour

Colour can be used to enrich space, enliven atmosphere and affect changes in mood. Colour evokes memory and response. Colour is the index to peace of mind. Life is color full with colours. We at Bhoruka Extrusions provide you with the choicest exotic RAL shades of colours from white to red to blue and to metallic. 

Long lasting impressions

Impressions are crucial to any architectural projects. Bright designs, surprising appearance, vibrant colours. Just the fact when it comes to protection of Aluminium profiles at a sea shore for about 1520 years thinks of Bhoruka extrusion. For all purpose Bhoruka Extrusions has a versatile powder coating line specially designed to provide eye catching surface finishes in different colours and combined high quality of surface finish taking very less working time .Facility to think of We can handle longer profiles to a length of 7.5Mtrs. We have advanced -treatment technology from, Italtecno, Italy, the world's leaders in pre-treatment chemicals. In addition, Bhoruka has incorporated the 9tanks process, which comprises of the latest eco - friendly non chrome chromate conversion which is bio degradable for best durability. A fully fledged analytical laboratory to analyze the pre-treatment process has also been analytical corporated. Adding feathers to our cap, we have powder spraying system supplied by the global leaders from ITwGema, Switzerland, who are the world's leaders in powder spraying systems ell known for there electrostatic and corona guns .with reciprocated and controlled coating thickness to ensure proper coverage a tall corners and crevices. This process is done in an enclosed, dust free region, atguns for atmosphere temperature to give acurate and high quality of a vibrant finish. The curing is done in conversed oven which has a close control of temperature for enhanced life and super durability. To offer customers a high quality of finished product, a final testing lab with all the equipments to carry out the tests to check the impact resistance, gloss level, dry film thickness and powder curring done. A production capacity of 2000 sq meters/ day, we are well equipped to meet our customer demands 2.5.1: Advantages of powder coating instead of other coatings 



Powder coatings contain no solvents and release little or no amount of Volatile Organic Compounds (VOC) into the atmosphere. Thus, there is no longer a need for finishers to buy costly pollution control equipment. Companies can comply more easily and economically with the regulations of the U.S. Environmental Protection Agency. Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging .Powder coated items generally have fewer appearance differences between horizontally coated surfaces and vertically coated surfaces than liquid coated items.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

 

The wide range of specialty effects are easily accomplished powder coatings that would be impossible to achieve with other coating processes. Curing time is significantly faster with powder coating as compared to liquid coating.

2.5.2 :Types of powder coating There are two main categories of powder coating: thermosets and thermoplastics. The thermosetting variety incorporates a cross- linker into the farmulation. When powder is baked ,it reacts with other chemical groups in the powder to polymerize , improving the performance properties. The thermoplastics variety does not undergo any additional action during the baking process as it flow to form the final coating. The mist common polymers used are: polyester, polyurethane, polyester-epoxy, straight epoxy and acrylics. Methylene chloride and acetone are generally effective at removing powder coating. Most other organic solvents (thinners, etc.) are completely ineffective. Recently the suspected human carcinogen methylene chloride is being replaced by benzyl alcohol with great success. Powder coating can also be removed with abrasive blasting. 98% sulfuric acid commercial grade also removes powder coating film .citation needed Certain low grade powder coats can be removed with steel wool, though this might be a more labor-intensive process than desired. Powder coating can also be removed by a burning off process, in which parts are put into a large high-temperature oven with temperatures typically reaching an air temperature of 300 - 450 °C. The process takes about four hours and requires the parts to be cleaned completely and re-powder coated. Parts made with a thinner-gauge material need to be burned off at a lower temperature to prevent the material from warping. 2.5.3: Pre Process- Part preparation processes and equipment Removal of oil, dirt, lubrication greases, metal oxides, welding scale etc. is essential prior to the powder coating process. It can be done by a variety of chemical and mechanical methods. The selection of the method depends on the size and the material of the part to be powder coated, the type of impurities to be removed and the performance requirement of the finished product. Chemical pre-treatments involve the use of phosphates or chromates in submersion or spray application. These often occur in multiple stages and consist of degreasing, etching, de-smutting, various rinses and the final phosphating or chromating of the substrate & new nanotechnology chemical bonding. The pre-treatment process both cleans and improves bonding of the powder to the metal. Recent additional processes have been developed that avoid the use of chromates, as these can be toxic to the environment. Titanium zirconium and silanes offer similar performance against corrosion and adhesion of the powder. In many high end applications, the part is electro coated following the pretreatment process, and subsequent to the powder coating application. This has been particularly useful in automotive and other applications requiring high end performance characteristics.

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Another method of preparing the surface prior to coating is known as abrasive blasting or sandblasting and shot blasting. Blast media and blasting abrasives are used to provide surface texturing and preparation, etching, finishing, and degreasing for products made of wood, plastic, or glass. The most important properties to consider are chemical composition and density; particle shape and size; and impact resistance. Silicon carbide grit blast medium is brittle, sharp, and suitable for grinding metals and low-tensile strength, non-metallic materials. Plastic media blast equipment uses plastic abrasives that are sensitive to substrates such as aluminum, but still suitable for de-coating and surface finishing. Sand blast medium uses high-purity crystals that have low-metal content. Glass bead blast medium contains glass beads of various sizes. Caststeel shot or steel grit is used to clean and prepare the surface before coating. Shot blasting recycles the media and is environmentally friendly. This method of preparation is highly efficient on steel parts such as I-beams, angles, pipes, tubes and large fabricated pieces. Different powder coating applications can require alternative methods of preparation such as abrasive blasting prior to coating. The online consumer market typically offers media blasting services coupled with their coating services at additional costs.

2.5.4:Powder application processes

Fig 17

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Fig 18

The most common way of applying the powder coating to metal objects is to spray the powder using an electrostatic gun, or corona gun. The gun imparts a positive electric charge to the powder, which is then sprayed towards the grounded object by mechanical or compressed air spraying and then accelerated toward the work piece by the powerful electrostatic charge. There is a wide variety of spray nozzles available for use in electrostatic coating. The type of nozzle used will depend on the shape of the work piece to be painted and the consistency of the paint. The object is then heated, and the powder melts into a uniform film, and is then cooled to form a hard coating. It is also common to heat the metal first and then spray the powder onto the hot substrate. Preheating can help to achieve a more uniform

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]





finish but can also create other problems, such as runs caused by excess powder. See the article "Fusion Bonded Epoxy Coatings" Another type of gun is called a tribo gun, which charges the powder by (tribo electric) friction. In this case, the powder picks up a positive charge while rubbing along the wall of a Teflon tube inside the barrel of the gun. These charged powder particles then adhere to the grounded substrate. Using a tribo gun requires a different formulation of powder than the more common corona guns. Tribo guns are not subject to some of the problems associated with corona guns, however, such as back ionization and the Faraday cageeffect. Another way to coat and protect from back ionization and the Faraday cage is with a special wave board created by Spectracoat.

2.5.5 : Other Method Of Coating: Powder can also be applied using specifically adapted electrostatic discs. Another method of applying powder coating, named as the fluidized bed method, is by heating the substrate and then dipping it into an aerated, powder-filled bed. The powder sticks and melts to the hot object. Further heating is usually required to finish curing the coating. This method is generally used when the desired thickness of coating is to exceed 300 micrometres. This is how most dishwasher racks are coated. 

Electrostatic fluidized bed coating

Electrostatic fluidized bed application uses the same fluidizing technique as the conventional fluidized bed dip process but with much less powder depth in the bed. An electrostatic charging medium is placed inside the bed so that the powder material becomes charged as the fluidizing air lifts it up. Charged particles of powder move upward and form a cloud of charged powder above the fluid bed. When a grounded part is passed through the charged cloud the particles will be attracted to its surface. The parts are not preheated as they are for the conventional fluidized bed dip process. 

Electrostatic magnetic brush (EMB) coating

A coating method for flat materials that applies powder with a roller, enabling relatively high speeds and accurate layer thickness between 5 and 100 micrometres. The base for this process is conventional copier technology. It is currently in use in some coating applications and looks promising for commercial powder coating on flat substrates (steel, aluminium, MDF, paper, board) as well as in sheet to sheet and/or roll to roll processes. This process can potentially be integrated in an existing coating line. 

Curing

When a thermoset powder is exposed to elevated temperature, it begins to melt, flows out, and then chemically reacts to form a higher molecular weight polymer in a network-like structure. This cure process, called crosslinking, requires a certain temperature for a certain length of time in order to reach full cure and establish the full film properties for which the material was designed. Normally the powders cure at 200 °C (390 °F) for 10 minutes. The curing schedule could vary according to the manufacturer's specifications. The application of energy to the product to be cured can be accomplished by convection cure ovens, infrared cure ovens, or by laser curing process. The latter demonstrates significant reduction of curing time. Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.6 : Nitriding: Nitriding is a heat treating process that diffuses nitrogen into the surface of a metal to create a casehardened surface. These processes are most commonly used on low-carbon, low-alloy steels. They are also used on medium and high-carbon steels, titanium, aluminium and molybdenum. In 2015, nitriding was used to generate unique duplex microstructure (Martensite-Austenite, Austeniteferrite), known to be associated with strongly enhanced mechanical properties. 2.6.1 :Processes The processes are named after the medium used to donate. The three main methods used are: gas nitriding, salt bath nitriding, and plasma nitriding 2.6.1.1: Gas nitriding Ingas nitriding the donor is a nitrogen rich gas, usually ammonia (NH3), which is why it is sometimes known as ammonia nitriding. When ammonia comes into contact with the heated work piece it dissociates into nitrogen and hydrogen. The nitrogen then diffuses onto the surface of the material creating a nitride layer. This process has existed for nearly a century, though only in the last few decades has there been a concentrated effort to investigate the thermodynamics and kinetics involved. Recent developments have led to a process that can be accurately controlled. The thickness and phase constitution of the resulting nitriding layers can be selected and the process optimized for the particular properties required. 

The advantages of gas nitriding over the other then variants are:

 Precise control of chemical potential of nitrogen in the nitriding atmosphere by controlling gas flow rate of nitrogen and oxygen.  All round nitriding effect (can be a disadvantage in some cases, compared with plasma nitriding)  Large batch sizes possible - the limiting factor being furnace size and gas flow  With modern computer control of the atmosphere the nitriding results can be closely controlled  Relatively low equipment cost - especially compared with plasma 

The disadvantages of gas nitriding are:

 Reaction kinetics heavily influenced by surface condition - an oily surface or one contaminated with cutting fluids will deliver poor results  Surface activation is sometimes required to treat steels with a high chromium content compare sputtering during plasma nitriding  Ammonia as nitriding medium - though not especially toxic it can be harmful when inhaled in large quantities. Also, care must be taken when heating in the presence of oxygen to reduce the risk of explosion

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.6.1.2: Salt bath nitriding In salt bath nitriding the nitrogen donating medium is a nitrogen-containing salt such as cyanide salt. The salts used also donate carbon to the work piece surface making salt bath a nitro carburizing process. The temperature used is typical of all nitro carburizing processes: 550 to 570 °C. The advantages of salt nitridizing is that it achieves higher diffusion in the same period of time compared to any other method. 

The advantages of salt nitriding are:

 Quick processing time - usually in the order of 4 hours or so to achieve  Simple operation - heat the salt and work pieces to temperature and submerge until the duration has transpired. 

The disadvantages are:

 The salts used are highly toxic - Disposal of salts are controlled by stringent environmental laws in western countries and has increased the costs involved in using salt baths. This is one of the most significant reasons the process has fallen out of favor in recent decades.  Only one process possible with a particular salt type - since the nitrogen potential is set by the salt, only one type of process is possible

Fig 19 Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.6.1.3 : Plasma nitriding Plasma nitriding, also known as ion nitriding, plasma ion nitriding or glow-discharge nitriding, is an industrial surface hardening treatment for metallic materials. In plasma nitriding, the reactivity of the nitriding media is not due to the temperature but to the gas ionized state. In this technique intense electric fields are used to generate ionized molecules of the gas around the surface to be nitride . Such highly active gas with ionized molecules is called plasma, naming the technique. The gas used for plasma nitriding is usually pure nitrogen, since no spontaneous decomposition is needed (as is the case of gas nitriding with ammonia). There are hot plasmas typified by plasma jets used for metal cutting, welding, cladding or spraying. There are also cold plasmas, usually generated inside vacuum chambers, at low pressure regimes. Usually steels are beneficially treated with plasma nitriding. This process permits the close control of the nitride microstructure, allowing nitriding with or without compound layer formation. Not only is the performance of metal parts enhanced, but working life spans also increase, and so do the strain limit and the fatigue strength of the metals being treated. For instance, mechanical properties of austenitic stainless steel like resistance to wear can be significantly augmented and the surface hardness of tool steels can be doubled. A plasma nitrided part is usually ready for use. It calls for no machining, or polishing or any other post-nitriding operations. Thus the process is user-friendly, saves energy since it works fastest, and causes little or no distortion. This process was invented by Dr. Bernhardt Berghaus of Germany who later settled in Zurich to escape Nazi persecution. After his death in late 1960s the process was acquired by Klockner group and popularized globally. Plasma nitriding is often coupled with physical vapor deposition (PVD) process and labeled Duplex Treatment, with enhanced benefits. Many users prefer to have a plasma oxidation step combined at the last phase of processing to produce a smooth jetblack layer of oxides which is resistant to wear and corrosion. Since nitrogen ions are made available by ionization, differently from gas or salt bath, plasma nitriding efficiency does not depend on the temperature. Plasma nitriding can thus be performed in a broad temperature range, from 260 °C to more than 600 °C.For instance, at moderate temperatures (like 420 °C), stainless steels can be nitrided without the formation of chromium nitride precipitates and hence maintaining their corrosion resistance properties. In the plasma nitriding processes, nitrogen gas (N2) is usually the nitrogen carrying gas. Other gasses like hydrogen or Argon are also used. Indeed, Argon and H2 can be used before the nitriding process during the heating of the parts to clean the surfaces to be nitrided. This cleaning procedure effectively removes the oxide layer from surfaces and may remove fine layers of solvents that could remain. This also helps the thermal stability of the plasma plant, since the heat added by the plasma is already present during the warm up and hence once the process temperature is reached the actual nitriding begins with minor heating changes. For the nitriding process H2gas is also added to keep the surface clear of oxides. This effect can be observed by analysing the surface of the part under nitriding (see for instance ).

Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

2.7 :Shot blasting : Abrasive blasting, more commonly known as sandblasting, is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface or remove surface contaminants. A pressurized fluid, typically compressed air, or a centrifugal wheel is used to propel the blasting material (often called the media). The first abrasive blasting process was patented by Benjamin Chew Tilghman on 18 October 1870. There are several variants of the process, using various media; some are highly abrasive, whereas others are milder. The most abrasive are shot blasting (with metal shot) and sandblasting (with sand). Moderately abrasive variants include glass bead blasting (with glass beads) and plastic media blasting (PMB) with ground-up plastic stock or walnut shells and corncobs. Some of these substances can cause anaphylactic shock to individuals allergic to the media. A mild version is soda blasting (with baking soda). In addition, there are alternatives that are barely abrasive or nonabrasive, such as ice blasting and dry-ice blasting.

2.8 :Tool Room Department A toolroom is a room where tools are stored, in a factory, a space where tools are made and repaired for use throughout the rest of the factory. In engineering and manufacturing, toolroom activity is everything related to tool-and-die facilities in contrast to production line activity. Originally a toolroom was literally in one room, but like emergency room, the term has been figuratively extended in both substantive and adjectival senses to all such places and the methods used there, regardless of the physical space. The name was originally styled toolroom or toolroom, but toolroom is now the norm in engineering and machining. 2.9 : Fabrication: Bhoruka Fabcons, a part of the Bhoruka group of companies is located at Hebbal industrial area Mysore and is in close proximity to Bhoruka Extrusions. The focus of Bhoruka Fabcons is to add value to the group's products and service which will directly create value for our customers via service, quality and price. The overall value so created will help our customers to a have a competitive edge in the market place.The overall capability’s of Bhoruka fabcons includes the following:       

CNC machining /programming Cut to length sawing Mitre cutting/ compound mitre Drilling /Chamfering Counter sinking Tapping Milling Assembling

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 

Vibratory deburring Packing

Here CNC machine is a five axis machining center which can do shapes with complex geometry, superior surface finish and high degree of manufacturing flexibility not normally found in other manufacturing methods. The machining service provides a wide array of product. These products span from very tightly tolerance components to various other products required for the varied industries. The mitre cuts saw is capable of various miter cuts, ranging from 230to 450 with the twin cutting head and is also able to deliver compounded angel imported from Italy.

2.10 :System housing Bhoruka Extrusions has the unique distinction of being the only extruder in India with whom globally reputed system houses are associated for their extrusion requirements. System Houses have stringent quality requirements as well as require total business privacy for their engineered/patented products .Following are the list of System Houses with whom Bhoruka Extrusion is the only extruder in India to be proudly associated with.  REYNAERS Reynaers Aluminium is a European developer of aluminium products for the building sector. The company also provides support for architects, fabricators, solar installers, project developers, investors and end users. The company, with its headquarters in Duffel, Belgium, employs over 1,500 workers in 37 countries worldwide and exports to 72 countries on 5 continents. In 2013 Reynaers achieved a turnover of 317 million euro’s.www.reynaers.in  ALUK GROUP S.P.A Aluk Group SPA, founded in 1969 in Verona, is one of the leading European companies in the manufacturing of aluminium systems for casement and sliding windows, doors, curtain walls and structural glazing both with and without thermal break. Alukaluminium systems are made up of patented designed aluminium extrusions and owned produced fittings and accessories. Aluminium sections can be outsourced to be locally extruded. Fittings, accessories, gaskets and technological know how shall be supplied directly from Italy.www.alike.it  European Façade Products (EFP) European Facade Products (EFP) is a Dutch based company.EFP is specialized in developing aesthetic, custom made Facade and Glazing systems to the highest architectural and technical standards.EFP has combined European Technology with efficient manufacturing techniques in order to serve the growing demand for high-tech, quality facade systemsFull dedication to quality, and more than 40 years of world wide experience in the development and marketing of aluminium facade systems, are the basis for all EFP Facade products & systems.www.europeanfacade.com  Schuco International KG Schüco Group develops and sells system solutions for windows, doors, façades, sliding systems, security technology and sun shading. In addition to these innovative products for residential and commercial buildings, the building envelope specialist offers consultation and digital solutions for all Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

phases of a building project – from the initial idea through to design, fabrication and installation. Machinery for fabrication and a 360° cycle of sustainability complement the range of products and services.www.schuco.de  Brital Ltd Brital Ltd was initially established to design and market aluminium curtain wall and Facade systems in the Gulf region of the Middle East. Brital is a UK company that has at its disposal some of the most experienced Facade designers in Europe. Several of the design staff have a Masters Degree in Facade Engineering, including our Technical Director.www.brital.co.uk  Airclos From the begining, AIRCLOS has earned a reputation as an aluminium systems specialist, enabling it to fast increase its sales and the scope of its operations. It thus managed to strike a perfect balance between meeting corporate objectives and offering the highest-quality, most innovative products.www.airclos.com

2.11:Maintenance (technical) The technical meaning of maintenance involves functional checks, servicing ,repairing or replacing of necessary devices, equipment, machinery, building infrastructure, and supporting utilities in industrial, business, governmental, and residential installations .Over time, this has come to include multiple wordings that describe various cost-effective practices to keep equipment operational; these activities take place either before or after a failure. Together, these functions are referred to as Maintenance, repair and overhaul (MRO). MRO is also used for Maintenance, repair and operations. Any activity—such as tests, measurements, replacements, adjustments, and repairs—intended to retain or restore a functional unit in or to a specified state in which the unit can perform its required functions. All action taken to retain material in a serviceable condition or to restore it to serviceability. It includes inspections, testing, servicing, classification as to serviceability, repair, rebuilding, and reclamation. All supply and repair action taken to keep a force in condition to carry out its mission. The routine recurring work required to keep a facility (plant, building, structure, ground facility, utility system, or other real property) in such condition that it may be continuously used, at its original or designed capacity and efficiency for its intended purpose. Maintenance is strictly connected to the utilization stage of the product or technical system, in which the concept of maintainability must be included. In this scenario, maintainability is considered as the ability of an item, under stated conditions of use, to be retained in or restored to a state in which it can perform its required functions, using prescribed procedures and resources.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Chapter 3 : Result Analysis 3.1 : Extrusion 3.1.1 : Advantages of extrusion process  Advantage– Low Cost Extrusion molding has a low cost relative to other molding processes.This stems, in part, from the efficiency of the process. Most extrusion molding uses thermoplastics, which can repeatedly undergo melting and hardening. Leftover materials, normally discarded as waste in other processes, can be reused. This lowers raw material and disposal costs. Barring mechanical failure or planned downtime, plastic extrusion machines operate continuously. This reduces the chances of inventory shortage and allows for 24 hours-a-day manufacturing.  Advantage – Flexibility Extrusion molding provides considerable flexibility in manufacturing products with a consistent cross-section. To picture a consistent cross-section, imagine cutting straight through a block of cheese in several places. No matter which pieces you pick up, they all maintain the rectangular block shape. So long as the cross-section remains the same, extrusion molding can produce complex shapes, such as decorative trims. With minor alteration to the process, manufacturers use extrusion molding for plastic sheets. Variation on the extrusion process also allow for the manufacturing of products that mix plastic attributes, such as hard and soft surfaces.  Advantage – Post-Extrusion Alterations The plastic remains hot when it leaves the extruder, which allows for post-extrusion manipulation. Manufacturers take advantage of this and use a variety of rollers, dies and shoes to alter the shape of the extruded plastic to fit their needs.       

Other advantages: It can easily create complex cross section Extrusion can be done with both brittle and ductile materials High mechanical Properties can achieved by cold extrusion Continuous operation Good Mixing (Compounding) Many types of raw materials can be used

3.1.2 : Disadvantages Of Extrusion:  Disadvantage – Size Variances When the hot plastic exits the extruder, it frequently expands. The expansion of the plastic at this stage of the process is called die swell. Predicting the exact degree of expansion remains problematic as it arises from different factors in the process. Due to unpredictable expansion, Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

manufacturers must often accept significant levels of deviation from the product dimensions or tolerance. While methods exist to limit this issue, the tolerance problem largely disqualifies extrusion molding as a method for precision parts manufacturing.  Disadvantage – Product Limitations The nature of the extrusion molding process places limits on the kinds of products it can manufacture. For example, plastic soda bottles narrow at one end to accommodate a cap, which normal extrusion molding cannot achieve. Alternatives, such as extrusion blow molding do provide an option for these types of products, but require investment in a different type of extrusion equipments.  Other Disadvantages are:  High initial or setup cost  High compressive force required

3.1.3 : Application Of Extrusion    

Extrusion is widely used in production of tubes and hollow pipes. Aluminum extrusion is used in structure work in many industries. This process is used to produce frames, doors, window etc. in automotive industries. Extrusion is widely used to produce plastic objects.

3.2 : Anodizing : 3.2.1: Advantages Of Anodizing: 1) Durability: Most anodized products have an extremely long life span and offer significant economic advantages through maintenance and operating savings. Anodizing is a reacted finish that is integrated with the underlying aluminum for total bonding and unmatched adhesion. 2) Color Stability: Exterior anodic coatings provide good stability to ultraviolet rays, do not chip or peel, and are easily repeatable. Ease of Maintenance: Scars and wear from fabrication, handling, installation, frequent surface dirt cleaning and usage are virtually non-existent. Rinsing or mild soap and water cleaning usually will restore an anodized surface to its original appearance. Mild abrasive cleaners can be used for more difficult deposits 3) Aesthetics: Anodizing offers a large increasing number of gloss and color alternatives and minimizes or eliminates color variations. Unlike other finishes, anodizing allows the aluminum to maintain its metallic appearance. 4) Cost: A lower initial finishing cost combines with lower maintenance costs for greater longterm value. 5) Health and Safety: Anodizing is a safe process that is not harmful to human health. An anodized finish is chemically stable, will not decompose; is non-toxic; and is heat-resistant to the melting point of aluminum (1,221 degrees F.)Since the anodizing process is a reinforcement of a naturally occurring oxide process, it is non-hazardous and produces no harmful or dangerous by-products. Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

6) Corrosion Resistance: Anodized aluminum is more resistant to corrosion than standard aluminum. Neither standard nor anodized aluminum can rust. However, they can still corrode when exposed to moisture, air, salt or other corrosion-inhibiting compounds or elements. But anodized aluminum is less likely to corrode than standard aluminum because they have a thicker layer of oxide. 7) Lubrication: While the single greatest benefit of anodized aluminum is its superior resistance to resistance, it also features better lubrication than standard aluminum. With aluminum is anodized, it creates deeper pores in the metal that allow for greater retention of lubricating oil or film. Standard aluminum has a smooth surface, so it’s unable to retain lubricating oil or film. 8) Dyeing: Anodized aluminum can also be dyed to produce colorful aluminum products. Standard aluminum typically doesn’t support dyeing. As a result, companies that use standard aluminum are restricted to its natural chrome color. Thankfully, this problem is easily solved by using anodized aluminum. Unlike standard aluminum, anodized aluminum can be dyed to achieve any color or combination of colors. How is anodized aluminum able to support dyeing? When aluminum is anodized, it’s exposed to acid chemicals like sulfuric acid that trigger the formation of a thicker oxide layer as well as a porous surface. The porous surface allows anodized aluminum to hold dye more effectively than the smooth, nonporous surface of standard aluminum. 9) Increased Adhesion: Finally, anodized aluminum offers greater adhesion for adhesives and primers. This is because the oxide surface of anodized aluminum has deeper pores that of standard aluminum. The pores are essentially holes in which adhesive, primers or liquids will flow when applied to the surface. As the anodized aluminum soaks up the liquids, it allows for greater adhesion 10) .Uniform surface finish for all metal shapes and textures: Anodising is a process which can be carried out prior to or after the transformation of the metal. Since it is an immersion process rather than an applied finish, anodizing provides a particularly uniform and regular finish on most metal shapes and textured surfaces such as perforated sheets, tread plates, linished or brushed metal, mesh material, stucco surfaces, etc. Anodising avoids the risk of localised high coating thickness or orange peel effect, typically associated with organic coatings on such surfaces 11) Quality controls: The tightly controlled quality assurance in the anodising process can be followed up on site without damage to the anodised surface. 12) Environmental benefits of pure anodized aluminium - 100% recyclable: One of the key advantages of aluminium over other materials is that it is can be recycled repeatedly through simple re-melting with minimal loss on each cycle. In Europe, more than 30% of aluminium consumption is satisfied with recycled aluminium and over 90% of the aluminium used in buildings is recycled at the end of the building's life. The recycling process requires only 5% of the energy required for the production of primary aluminium - a significant contribution to environmental sustainability. 13) Anodised aluminium is unique, comprising only pure aluminium, its alloying elements and oxygen. As pure aluminium, it is fully recyclable without inter vening chemical processes and emissions. Because of this and the ready market for quality aluminium scrap, the anodized aluminium will have a cash value to offset the cost of demolition at the end of the useful life of the building.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

3.2.2 :Disadvantage Of Anodizing:        

Can only use specific grades of aluminium for this process, Cannot be used on Stainless Steel, which is durable to mortar, salt, chlorine and marine environments, This method draws from the base metal so it can be subject to colour variations. In high grade metals a 95% match is possible between batches, in low grade metals no match is possible, Consequently harder to replicate consistency between batches compared to plating,  The most expensive solution for small quantities (requires a higher-grade alloy in addition to the already high set up costs). Limited color selection.  Because of the chemicals used in the anodizing process, you are greatly limited on the color selection for your next project or product. Anodizing does not offer you the extended warranties as Superior Pigmented Painted Products. Touch-up of anodized product that is severely damaged in your shop or the field is more noticeable than air dry touch up paint for painted products

3.2.3 : Application Of Anodizing :       

Structural and architectural categories of all types, appliances Commercial and residential building products Food preparation equipment Furniture Sporting goods and boats Motor vehicles components Jewelry and artwork

3.3 : Powder Coating 3.3.1 :Advantages of P.C :      

3.3.2   

A wide range of finishes can be achieved using this process, Provides a layer of protection against corrosion, scratches/chipping and fading, One of the most economical, longest lasting, and most colour-durable quality finishes available on virtually any type of metal, Achieves a consistent colour finish across the metal, Powder coatings can produce much thicker coatings than conventional liquid coatings without running or sagging, Non-toxic and less flammable than wet spray paint finishes : Disadvantages Of P.C : Powder coats can leave an 'orange peel' texture on the metal The process involves moderate set up costs due to the machinery involved  Powders cannot be mixed to obtain different colours 

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

3.3.3   



: Application Of P.C: Powder coating is an ideal method if you want to achieve a specific colour match. It can be applied to a range of substrates including steel, copper and aluminium and offers a durable architectural finish. Suitable for both internal and external applications. The latter requires a specific metal and in some instances a further treatment process to cope with saline environments. Our Team of experts can advise which finishing method is most suited to your application. In general it works well with up lights and wall lights as it is durable and will not get scratched easily.

3.4 : Nitriding: 3.4.1 : Advantages Of Nitriding :           

3.4.2         

Nitriding  produce great surface hardness of materials.  Nitriding process produce material have greater resistance to corrosion and wear. this high hot hardness.  high fatigue life. resistance against Abrasive and adhesive  wear is increased.  Nitriding is improved the fatigue properties of materials.  Nitriding process required less time.  Nitriding materials have higher endurance limit under the bending stress.  Hardness of materials achieved without   using the oil ,air quench. no cracks produce  due to Nitriding   process is main advantages of Nitriding.  Nitriding process is clean process because this process  not  produce carbon.  : Disadvantage Of Nitriding : In Nitriding process used medium is costly is main disadvantages of Nitriding  High furnace cost required for Nitriding process.  No heat treatment is used after Nitriding.  Due to Nitriding Thin case depth. white layer.  Nitriding  process is application only for alloy  steel containing Nitriding  elements.  long cycle  required.  In Nitriding process technical control is required.  hardness is  reduced if materials is  reheating  for  enough time.

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Chapter 4 : Conclusion The one month, internship in Bhoruka Extrusion Pvt. Ltd. has been unique experience to us. Bhoruka Extrusion Pvt. Ltd has gone for modernization and diversification by improving the existing methods of manufacturing and installation of an additional extrusion press and anodizing plant.Its having conventional technology in the company. During my internship period, i had seen the various instruments and apparatus in the industry. The highly sophisticated instruments that work precisely must be operated with intense care for optimum use. I could acquire a lot of information regarding the latest instruments and working procedure. Because of aluminum inherent qualities like strength to weight ratio, corrosion ,resistance, aesthetic and versatality etc, scores over other materials. The aluminum extrusion has great potential as many new applications are being explored every year. In BEPL we got to see how aluminum is converted from raw material to final product , through varies step like extrusion with different die patterns, anodizing, powder coating , nitriding and packing , followed in sequential order. And quality of the product will be the main concern. Apart from all, the training was very interesting a with lots of things to be learned. It helped us to acquire knowledge on punctuality, regularity and working environment in industries. The friendly working environment is BEPL will remain in our mind in near future. Hence, we can say that our goal of attending the internship is fulfilled. We acknowledge the great help of Bhoruka Extrusion Pvt. Ltd.

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Chapter 5 : Certificate Of Internship

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Internship Title : Extrusion Of Aluminum Name : Madhushree K [4MT16ME064 ]

Chapter 6: Reference / Bibliography 

    



Backus, Robert G. Boshold, R. F.: Johannisson, Thomas G.: Noble, PauD.; Pfeffer, Jerome B.; Schiebold, Ted A; Spearman, J. E. (1998) [1984].Drawing, extruding, and upsetting". In Wick, Charles; Benedict, JohnT; Veilleux, Raymond F. Tool and manufacturing engineer handbookvol. 2 (4th cd.). SME. ISBN 0-87263-135-4. Oberg, Erik; Jones, Franklin D.; Horton, Holbrook L. Ryffel, Henry H.(2000), Machinery s Handbook (26th ed), New York: IndustrialPress, ISBN 0-8311-2635-3. "The Practical Anodizing of Aluminium" by Walter Willy Georg Hubnerand Adolf Schiltknecht. Macdonald and Evans, Ltd., 1960. . "The Technology of Anodisingini by Arthur William Brace.Robert Draper Ltd., 1968. ISBN 9780852180266. Anodizing and Colouring of Aluminium Alloys" by Satoshi Kawai.FinishingPubns Ltd.2002. ISBN 978-0904477245. Paperbackedition: ISBN 0-904477-24-X. Electropolishing, Anodizing and Electrolytic Pickling of Metals" by N.P Fedot’ev and So.Ya. Grilikhes. Translated from Russian by A.Behr. Robert Draper, Ltd., 1959. Library of Congress Number: TS 643.F413. “The surface treatment band finishing organization and its alloys”. BywernickS. Pinner and P.G Sheasby.2 volume .Finishing Pubns Ltd, 2001.ISBN 978-0904477238. Library of congress number : TS555.S54x2001.

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Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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Department Of Mechanical Engineering Mangalore Institute Of Technology And Engineering, Moodbidri.

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