VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018

INTERNSHIP REPORT AT
BILVA MOULDS PVT LTD

SUBMITTED BY

Mr. Veeresh B (1SG18ME438)

UNDER THE GUIDANCE OF

Internal guide External guide
Mr. Pramod SV Mr. Jairam.S
Assistant professor Plant head bilva moulds
Bengaluru Bengaluru

DEPARTMENT OF MECHANICAL ENGINEERING

SAPTHAGIRI COLLEGE OF ENGINEERING
(Accredited by NAAC with “A” grade)
( An ISO 9001:2015 & ISO 14001:2015 Certified Institution)
(Affiliated to VTU, Belagavi and approved by AICTE, New Delhi)

DEPARTMENT OF MECHANICAL ENGINEERING

14/5, Chikkasandra, Hesarghatta Main Road, Bengaluru-560057
 CERTIFICATE

This is to certify that veeresh B (1SG18ME438) student of Sapthagiri College of Engineering,

Department of Mechanical Engineering has successfully completed the internship on at BILVA
MOULDS PVT LTD under the guidance of Mr.jairam S GA towards partial fulfillment of the
award of Bachelor of Engineering in Mechanical Engineering at Sapthagiri College of Engineering
affiliated to Visvesvaraya Technological University, Belagavi during 08-03-2021 to 08-04-2021. It
is certified that the above mentioned student has successfully completed the internship and submitted
the internship report in due time.

------------------------ ----------------------- --------------------

Mr.Pramod SV Dr.P Mahadevaswamy Dr.R G Deshpande
Signature of Guide Signature of HOD Signature of the
Internship coordinator

Examiner
Name of the examiner Signature with date
1._________________ ________________
2.________________ _______________
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the completion of any task would
be incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement ground my efforts with success.
We consider it as a privilege to express my gratitude and respect to all those
who guided me in completion of internship.
We thank Dr. H.Ramakrishna, Principal, Sapthagiri College of Engineering,
for the encouragement and facilities provided to carry out this work successfully.
It’s a great privilege to place on record my deep sense of gratitude to
Dr. P MAHADEVASWAMY, HOD of Mechanical Engineering, who for his
continuous support and advice.
We would like to express my hearty gratitude to my guide
Mr. Pramod SV, Assistant Professor, Department of Mechanical Engineering,
Sapthagiri College of Engineering, for his timely advice and regular assistance
throughout the work.
We thank all the teaching and non-teaching faculty members who have helped
me directly or indirectly.
Finally, We also thank our families and friends for their co-operation and
motivation to complete this internship successfully.
 Internship Report on “bilva moulds ”

ABSTRACT

Tool making is one of the trades in which a systematic approach before proceeding with any
practical work of the tool is required. Detailed study of all processes should be done i.e.
structural analysis, design analysis, process planning and manufacturing process etc..

This project report gives ideas regarding the different factors to be considered while
starting off a new tool. It also helps a fresh toolmaker to understand how to meet the tolerance. It
also gives a brief idea on the defects and remedies after the components are molded. It also gives
information about the estimation and costing, before and after manufacturing of tool

An earnest attempt has been made to cover the complete tool contents, which include
various steps to make the tool in the most economical method with high degree of accuracy in
its functional aspects within the given time. This project report gives a brief information
about design and manufacturing process of plastic Injection Moulds.

This presents an idea of fundamental necessary for processing the tool and to give a clear
picture of manufacturing process, i.e., sequence of machining operations involved during
manufacturing, assembly of moulds and in the trials.

 Department of Mechanical Engineering, SCE, B’lore Page 1

Internship Report on “bilva moulds ”

TABLE OF CONTENTS

Chapter Chapter Name Page

No. No.
1. INTRODUCTION…………………………………………....... 02

2. COMPANY PROFILE……………………..………………….. 03-04

3. ABOUT BILVA MOULDS …………..………………........ 05-09

4. TOOL LIFE MONITORING………………………………… 09-10

5. OBJECTIVES OF THE STUD……………………..………... 10-11

6. ACTIVATES………………………….…….… 11-14

ORGANIZATIONAL PROFILE…………………………….

SWOT ANALYSIS……………………………………

FINDINGS SUGGESTION…………………………..

7. CONCLUSION……………………………………………. 14

8. REFERENCES………………………………………………... 15

 Department of Mechanical Engineering, SCE, B’lore Page 2

Internship Report on “bilva moulds ”

CHAPTER 1:INTRODUCTION

• Organization study refers to the study of the organization as a whole and

getting familiar with various functional department in the organization this
study was conducted in BILVA MOULDS PVT LTD. Peenya II stage
Bangalore.
• A bilva mould has a well trained team of engg man of production shop which
is equipped with high productive good quality machines. Bilva products range
is automatic interior parts/exterior parts/grills & plating parts automotive two
wheeler parts appliances parts health care parts etc. BILVA MOULDS PVT
LTD” is highly quality conscious and service oriented and willing to improve
in those terms. We have an impressive record of satisfied customers to our
credit. As we build and maintain our company’s environment, it is important
to have a strong foundation. That is why “BILVA MOULDS PVT LTD” has
the strength of well experienced engineering team who represents the best
talent in the industry.

 Department of Mechanical Engineering, SCE, B’lore Page 3

Internship Report on “bilva moulds ”

CHAPTER 2: COMPANY PROFILE

• BILVA MOULDS PVT LTD moulding unit is ISO 9001:2008 Certified.

Established manufacturing sector in the year 2005 in the name of BILVA MOULD
TECHNOLOGIES. We chose development of plastic injection moulds and components, with
the objective of providing total solution and the expertise that we have in this field. We have
changed our business form to BILVA MOULDS PRIVATE LIMITED in the month of
August 2013. Company producing wide range of automotive parts more & more.
“BILVA MOULDS PVT. LTD.” is proud about its achievements in resulting
products like ,

 Volks Wagen logo & letters moulds.

• Radiator fan.
• Radiator shrouds.
• Electrical cover boxes.
• Air bag choot channel for “FORD”.

Our prestigious customers.

 Department of Mechanical Engineering, SCE, B’lore Page 4

Internship Report on “bilva moulds ”

 General Motors.
 TAFE.
 Bright Auto Plast Pvt.Ltd. (Chennai).
 Brakes India.
 TGKL (Toyota Gauss Kirloskar Ltd.)
 Sundaram plastics.
 Kongovi Electronics Pvt. Ltd.
 Stopak India Pvt. Ltd.
 Mate (Chennai)

 Department of Mechanical Engineering, SCE, B’lore Page 5

Internship Report on “Bilva moulds ”

CHAPTER 3: ABOUT BILVA MOULDS .

Products:
RADIATOR SHROUND
RADIATOR
SHROUND
FROM
CHEVEROLE
T ENJOY CAR

GENERAL PLANT PROCESS

1. RADIATOR SHROUD.

 Department of Mechanical Engineering, SCE, B’lore Page 6

Internship Report on “Bilva moulds ”

The cooling fan and the water pump are installed on the same shaft and both are
driven by a belt that's connected to the engine. The job of the cooling fan is to
circulate air through the radiator to discharge engine heat into the surrounding air.
Electric cooling fans are more efficient and clutches allow the fans to operate only
when needed. Aluminum fan shrouds are lighter than standard OEM shrouds. This
basic component is often overlooked, but it plays a huge role in engine cooling and it
secures the fan blades in place. Without the shroud, the fan blades could potentially
damage other vital components in the engine bay.

2. ENGRAVING MACHINE

Engraving is the process where in certain details are engraved on the outer diameter of
the tube. Tubes are cut and then engraved with special codes. These codes give a
unique identification to the tube including diameter of tubes, part number, length and
other important specifications. It is then moved on further operation.

3. LATHE MACHINE

 Department of Mechanical Engineering, SCE, B’lore Page 7

Internship Report on “Bilva moulds ”

An engraving tubes are moved to lathe machine for further operation. In lathe these
operations like facing, weld chamfer, band turning are machined. It acts as an
auxillary machine for CNC. Hence it reduces CNC machining time.

4. CNC MACHINE

The critical operations are conducted in CNC machines. Operations like facing with
tolerance , boring with tolerance , threading with tolerance +0.30, and
grooving with tolerance are done. There are two CNC machines to conduct all
these operations. It is having 8 tool holders in its turret. And it is 3 axis CNC
machine.

5. SKIVING AND ROLLER BURNISHING MACHINE

 Department of Mechanical Engineering, SCE, B’lore Page 8

Internship Report on “Bilva moulds ”

In this process tube internal diameter is bored by skiving operation to remove

excess material and maintain uniform diameter throughout the tube length.

Burnishing operation is carried out to maintain high degree of surface finish and
uniform diameter in the tube. Internal diameter which is the most important
requirement for hydraulic cylinder are performed in this machine. The tolerance for
Burnishing would be with in 30 microns.

The surface finish and mean tolerance is maintained in cylinder internal diameter

For the cylinder performance there should be no line marks either horizontal or
lateral allowed in internal diameter.

6. DRILLING MACHINE

In drilling machine drilling and spot facing are carried out as per drawing which is
required for pipe welding to be done on tube outer diameter. This enables the
hydraulic oil flow to the cylinder. There was only one drilling machine the plant.

 Department of Mechanical Engineering, SCE, B’lore Page 9

Internship Report on “Bilva moulds ”

7. RADIUS FORMING MACHINE

After drilling tubes are moved to radius forming machine. Concave surface radius are
produced in order to reduce burr formation and hence prevent wear. This is done by
ball pressing on the drilled port. This gives perfect finish for drilled hole.

8. WELDING MACHINE

Welding process is carried out by robotic welding. In this process tube and cap and
cover is welded through robotic welding, for consistent welding results welding is
programmed to achieve the weld requirement as per drawing. During static testing of
this tube sub assembly, there should be zero weld leakages. The drawing also calls for

 Department of Mechanical Engineering, SCE, B’lore Page 10

Internship Report on “Bilva moulds ”

certain angle to be maintained between tube and cap and cover. This welding is
carried out using argon CO2 gas which is used as a shield for welding.

CHAPTER 4: TOOL LIFE MONITORING

Tool-Life Definition
1. The tool life is the duration of actual cutting time after which the tool is no longer
useable.
2. There are many ways of defining the tool life and the common way of quantifying
the end of a tool life is by a limit on the maximum acceptable flank wear.
3. With a good application and when properly applied, a tool life management system
can dramatically increase for a CNC machine tool.

Advantages
 Insert life monitoring maximizes service life of both the tool and machinery.
 The insert can be changed before failure and hence reduces part rejection.
 Non conformance is reduced.
 By maintaining mean tolerance the continuity in part production can be
achieved.
 Surface finish and tolerance can be improved with the reduction of insert wear
and damage.
 Cost of insert is around Rs 50 to Rs 150 but the cost of tubes are around Rs
2000 to Rs 5000 therefore changing of insert at right time is better
compensation for tube damage.
 By this it saves around Rs 1900 to Rs 4500.

Proposed work
We were assigned an experimental investigation of finding optimum tool life to
achieve an understanding of number of components produces by tool in CNC and
Burnishing machine for operations such as grooving, boring, threading and skiving
respectively. Various factors such as speed, feed, depth of cut, play an important role

 Department of Mechanical Engineering, SCE, B’lore Page 11

Internship Report on “Bilva moulds ”

in the tool life. In this we are operating at constant speed, feed, depth of cut. The tool
life has been evaluated accordingly.

CHAPTER5:- OBJECTIVES OF THE STUD

• To the study about company profile

• To know vision & mission of the company.To know organizational
activities in all functional areas and relat this to theoretical
knowledge acquired.To analyze the strength weakness opportunist
and threats of company.

This project provides knowledge about tool life analysis of tools used in CNC and
Burnishing machine of this industry. Analysis of data of tool life is done and recorded
in excel sheet and average life is found.

 Average tubes machined in Boring insert(TNMG16048) = 127

Therefore the insert need to be changed between 120 to 125 tubes.
 Average tubes machined in Grooving insert(2.4ISCAR) = 202 Therefore the
insert need to be changed between 195 to 200tubes.
 Average tubes machined in Threading insert(16IRM200ISO)=74
Therefore the insert need to be changed between 68 to 72 tu0bes.

CHAPTER 6: ACTIVATES
• Product development.
• Mould design.
• Injection moulds for plastic componets.
• Proto moulds and components.
• Supply of injection mould components.

ORGANIZATIONAL PROFILE
• Functional departments of bilva moulds
• Production department

 Department of Mechanical Engineering, SCE, B’lore Page 12

Internship Report on “Bilva moulds ”

• Marketing department
• Finances/accounts department.

• Maintences department
• Directing coordinating reporting organizing staffing and budgeting is the part
of personal management.

SWOT ANALYSIS

• Strength:- Better product quality & strong innovation skills the

company follows strict measures in developing better product
• The company has modern manufacturing facility with maximum
capacity
• An ISO 9001-2008 certified company
• Creating branded experiences
Weakness
• Power may miscarriage here may result in utilization of capacity
high oriented cause due to exassive labor
• Raw material cost & availability of the raw material is affected in
every reason
• Opportunities :- increasing buying power & customer base in
India as there been anyone moves intake for furnace
• Production units present of production unites in four states help the
company to widen its market in national and international level
• Threats:- cost excess investing carriers an additional cost which
can affect the line of credit.

 Department of Mechanical Engineering, SCE, B’lore Page 13

Internship Report on “Bilva moulds ”

FINDINGS SUGGESTION:-
• It takes times of the find good supplies build the partnership not in
china but all over the world the expectation & understanding would
be very important success. There an lots of different standard
mould makers in Indian
• The most import rent & different thing id to choose the right mould
maker for a company at the beginning
• Suggestion:- there is no doubt bilva moulds is very organized
moulds company still there is always room for improvement and
following are some measures suggest for following the
performances company
• Company should to create interdepartmental coordination and
harmo

 Department of Mechanical Engineering, SCE, B’lore Page 14

Internship Report on “Bilva moulds ”

CHAPTER 6: Conclusion

The study indicate the positives aspect is that the company insist on good labor
relation and work for good harmony with in the organization more than earring profit
the company concentrates on many other aspects that it needs to survive the
completion in the market. By manufacturing of this COLD RUNNER mould, I have
acquired knowledge regarding mould-manufacturing process, including design study,
process planning, and electrode planning, defects and remedies and trial procedures.
The problems faced during the manufacturing were brought to the notice of senior
toolmakers and our in-charge who helped us to solve them with their useful advices.
One-year in-plant training program in “BILVA MOULDS PVT LTD,” where
I had an opportunity to come across this project was of very much importance
to build my career and also it gives exposure to modern industrial working
atmosphere.

 Department of Mechanical Engineering, SCE, B’lore Page 15

Internship Report on “Bilva moulds ”

CHAPTER 7: REFERENCES
 “INJECTION MOULD DESIGN” - R.G.W.PYE.

 “PRODUCTION TECHNOLOGY” - S.K.HAJRA CHOUDARY.

 “MATERIAL SCIENCE & METALURGY” - O.P.KHANNA.

 “ESTIMATION AND COSTING” - BANGA & SHARMA.

 “THEORY OF MOULDS” - R.S.NAGESH.

 www.bilvamoulds.com

 Department of Mechanical Engineering, SCE, B’lore Page 16