TRAINING REPORT

July 22 August 6
Prepared by

Ravi Teja
Material Research
HGID
TRAINING SCHEDULE NEW JOINEES
S/No
.
Training Equipment Used Trainer Time
July
22 23 24 25 26 27 28 29 30 31 1 2 3 5 6 7
1
Creep Testing &
Lubricant Test
Testing Jig & Heat Oven
Adarsh
San
I Half
II Half
2 Microscope Analysis
1.Equipment Knowledge
2.Analysis on sample
Amit
San
I Half
II Half
3 X-Rite Measurement
1. Spectrophotometry
2.Measurement and
Operation of Equipment
Manu
San
I Half
II Half
4
Paint Thickness
Measurement / Du
Pont Impact Testing
1. Equipment Know How
2.Sample Measurement
Practice
Manu
San
I Half
II Half
5 Bony Polymers Visit
Visit to Bony Polymers for
MP tubes
Adarsh
San
I Half
II Half
6
KNP Trial - Pearl
White System
Visit To KNP Factory
Manu
San
I Half
II Half
7
Fabric / Leather
Abrason testing
Leather , PU Leather ,
PVC Leather , Fabric
Study & Abrasion
Manu
San
I Half
II Half
8 Final Report
Yokoyama San &
Yamamoto San
12:30
PM


Final Report to
Yamamoto San &
Yokoyama San
Activity
Short Summary
Report
Activity
Schedule
1 / 17
Material
Overview
HES,SPEC
Study
Material
Development
Part Testing
Sample
Preparation
Sample
Testing
Evaluation
Training Flow
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S.No. Training Item Content Result
6 Abrasion Testing
Test requirement ,test procedure,sample
preparation,result evaluation
learn the importaance and requirements for
evaluation of abrasion testing for evaluation
of any faabric of interiors
7 Du Point Impact Testing
Impact testing as per HES,test procedure,
speciemen preparation & testing
learned use of impact tester to evaluate the
performance,and strength of plastic
materials as per their application
5 Paint Process, (L,a,b) significance, X-Rite
Learnt how to find paint reflection values
for different samples and analyse the data
as done at KNP visit
3
4 Functions, Changing Lens, Manual Study Microscope analysis
Finding crack,microstructure analysis ,grain
structure of polymers/metals.
Air Cleaner Box Noise test Support Activity to Manu San
Learnt noise test is needed to evaluate the
the performance during actual work
conditions
Sample Preparation, test standard, Break
even point,results and correlation.
Creep Testing 2
Learnt how to find the break even point any
plastic under prolonged stress
Training Summary
HES: different polymer grades as application;
Sample preparation for testing and
evaluation;
DWG of Interior & exterior parts of cars
Learnt use & application of different
polymers/resins in cars as per the
requirements at each section; also
learnt material evaluation method for each
part
Plastic & Rubber Materials
-Interior & Exterior
1
3/17
Summary
3 / 17
1.1 Plastic Materials
o Interior Materials
o Exterior Materials
HES PP -
Interiors
HES PP-
Exteriors
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PP Materials Classification
Test Steps
Test Car : BRIO 2013 model
Unit : dB/RMS/A Fast
Speed vs Noise values are tabulated
Test Steps
Sample Preparation(80x40x3 mm3)
Sample is fixed on the jig
Test the creep properties of a material,
when subjected to a prolonged tensile
or compressive load.
Temperature: 80 deg C
Checked for any cracks are formed
Distance from the origin point is taken
Sample: Xenoy



2. Air Cleaner Box Noise Test 1. Creep Testing
50
60
70
80
90
100
0 2000 4000 6000
d
B
/
R
M
S
/
A


Engine RPM
VA Material
Current
Material
I can find break even point of any plastic
material at particular temperature under
prolonged stress in future
2
2
3
2
4
2
2 2
10
1
1
2

)
`

|
|
.
|

\
|
=

t X
a
b
a a
b
c
Checked the variation of noise vs engine RPM
for both VA & Current material and results was
OK
6 / 17
3.Microscope Analysis
S.no. Function Used
1. Remove Glare When areas with intense light reflection appear
white
2. Depth Composition When some parts of the image are out of focus
3. HDR When high colour gradation images are required
4. Sharpening Image To enhance contours in vivid colours
5. Markers To mark some specific area
6. Measuring angles ,Distance To get geometrical specs
7. Image Stitching To produce wide-view images.
Learnt how to use different functions in microscope that is present in HGID lab and
applied the same for the verification of corrosion in MP tube
Digital Microscope
VHX-1000 series.
20x , 500x, 1000x
7 / 17
JSR- 50X
With Cleaning- 50X
Without Cleaning- 50X
Zeon- 50X
Due to the difference in the results, a visit for counter-measure planned.
Test Results by HGID:
OK
Test Result by Bony Polymers:
NG
Without Cleaning
8 / 17
Welding Sealing
Primary
Treatment
Electro
Deposition
Primer Base Coat Clear Coat
Paint Process
1.Degreasing
2.Surface Activation
3.Zinc Phosphating

PAINT TYPE L a b
SY43 93.14 -1.31 +8.75
79.09 -1.39 -1.29
77.72 -1.29 +1.10
SY12 95.02 -0.22 +7.76
84.94 +0.39 +8.12
The samples were types of white colour used in other companys car models
4.X-Rite Measurement:






Multi-angle Spectrophotometer
For colour measurement
Measures: Chromatic region parameters (L,a,b)
& Flop Index (F.I.)
Angles: 15,25,45,75,110 deg



Angles L a b
25
45
75
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Model Angl
e
Bonn
et
Front
Bump
er
Door Side
View
Mirro
r
Trunk Rear
Bump
er
Roof
Honda
Amaze
25 52.9 34.1 61.3 47.8 68.9 47.8 44.7
60 80.7 91.7 92.2 84.8 90.8 84.8 76.9
80 94.9 72.2 98.3 95.2 98.2 95.2 93.3
Suzuki
Dzire
25 8.1 20.5 9.4 1.2 36.3 58.3 35.8
60 20.1 18.4 51.8 3.3 56.4 76.1 54.6
80 46.3 31.2 66.0 11.0 70 80.6 55.7
Hyund
ai
Verna
25 33.0 35.6 14.0 2.3 29.1 25.8 26.6
60 67.8 75.9 57.7 41.6 56.5 57.3 67.7
80 68.9 73.3 18.0 53.6 70.2 64.0 75.7
Understood the working of the instrument and took reading for three different cars at
different areas of the Exterior plastic parts after Molding.
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5 .Gloss Meter
Test Steps :

Sample Preparation
Loads used 500gm, 1000gm
Heights we have used 50cm,45cm,35cm
Find the Break point
Convergence & Confirmation of result
Samples EX2 Machino Polymers India
6.Du Pont Impact
Test Samples
Observed no breaking of the sample till 4.9 joules and similarly in future I can find the breaking
point or maximum impact the material can absorb in deciding which material to use ( we want
maximum energy to absorb instead of cracking, as while minor accidents also it should not be
damaged)
11 / 17
5. Abrasion Testing
NG
OK
Crack observed with
peeling at edges
Test Process
Cutting & preparation of test samples as
per spec HES D6506
Prepare samples for Wet Gakushin or Dry
Gakushin
Loading & setup of equipment and start
cycles -30,000 for dry & 1000 cycles for
wet Gakushin
Evaluation of Result by checking the
Appearance & peeling as given in Spec
Sample Used 2TP Seat Fabric
2.Rotary Type Abrasion Tester
Test Process
Cutting & preparation of test samples as
per spec (Diameter of sample used
115mm)
Loading & setup of equipment and start
as per given spec
Clean the abrasive wheels by sand
paper after every 1000 cycles for 20
rounds
Evaluation of Result by checking the
abrasion as per the grades in given spec
Sample Used 2TP Seat Fabric
Test Sample
Observed
some peeling
1.Gakushhin type friction Tester
From this we can simulate the rupture between human body with the seats and liquids that may
pour on seats sometimes
12 / 17
Title : Bony Polymers factory visit
Contents:
Processing of MP tubes




Cleaning of Extruder



Purpose : To understand the processing of MP tubes and Cleaning of Extruder
Conclusion: Bony Polymers visit is very satisfactory and one flaw found is there is
no clear work instruction for cleaning is attached near instrument.
Learnt the processing of tubes
Why cleaning is very essential in Extruder
Meeting Date 31 July13
Meeting Place Bony Polymers
HGID Member. Yamamoto , Manu
san, Adarsh San,
Shuchi san
Compound
Storage
Extruder
Cleaning
Hopper
Feeding
Extrusion Knitting
Adhesives
Cooling
Anti
sticking
Speed
control
Cutting
Curing
cleaning
Removal of
existing material
from barrel head
Removal of
existing material
from hopper
Removal of existing
material from barrel
Cleaning of
the nozzle
Feeding the
new material
Removal of
first few (5-10)
tubes with
impurities
Summary- Visit
13 / 17
Title : Kansai Nerolac Paints factory visit
Contents:
Process









Purpose : Pearl White Trial
Conclusion:
In case of Mica Base we observed both DFT & Pigment Conc are effecting, So we need to
control both to make optimization
In case of Base Coat there is no significant effect observed
Concluded Mica Base is a key parameter
Meeting Date 1 Aug13
Meeting Place KNP Bawal
HGID Member. Yamamoto , Manu
san, Manu san,
Shuchi san
Summary- Visit
IC White Baking
NH-624
CB
CC Baking
0
0.5
1
1.5
2
2.5
3
0 5 10 15
FI
DFT
MB FI vs DFT
20% UP
STD
20% Down
Series4
60
70
80
90
0 5 10 15
L
DFT
BC L(75) vs DFT
20% UP
STD
20% Down
Series4
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Seminars / Tasks
S.No. Date Topic Given By
1. 20 July,2013 Introduction to Polymers &Rubbers Adarsh San
2. 22 July,2013 Limit Strain Test Method Adarsh San
3. 24 July,2013 Colour Comparison of Car Models Manu San
4. 25 July,2013 Paint application Manu San
5. 25 July,2013 Paint thickness measurement Manu San
5. 26 July,2013 2MD Parts Investigation Manu San
6. 26 july,2013 Thermal Cycle Test Spec for Plastic
Materials
Manu San
7. 30 July, 2013 Initial R-theme Proposal Manu San
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Training
Conclusions:
The training is very helpful in first-hand experience of works at HGID.

The exposure to various plastic and rubber materials used in cars will be
beneficial in the future working.

Material knowledge, testing and process know-how which learnt daily
from the mentors are essential to any R&D, and hence will be useful in
the future.

Study of various test methods and their importance is necessary for
future localization & development ,and will try to contribute to HGID.

Study of fabrics/plastics/rubbers will help to apply it in the future materials
for Honda Cars.

Will try to Give my best contribution to HGID, with the knowledge and
experience gained through the training.

16 / 17
Acknowledgements
Thanks to Yokoyama San and Yamamoto San :
For their continuous guidance and support,
And hope to learn more from them in the future.

Thanks to Adarsh San and Manu San:
For their mentoring, daily training and introduction to the
HGID culture.

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