BRAKE

1
BRAKE FUEL LINE

SUBMITTED BY- PANKAJ and SUNITA
RANI
MECHANICAL ENGG.

ROLL NO-12305 12326 SEM- 5th

DRONACHARYA COLLEGE OF ENGG

GURGAON
2
CERTIFICATE This is to certify that the
project entitled Brake Fuel Line submitted by
Mr. Pankaj Miss. Sunita Rani is a bonifide
record of work carried out by her under my
supervision from 15th June 2011 to 31st July
2011.the contents of this thesis, in full or in
parts have not been submitted to any other
institute or university for the award of any
degree. Mr. Mohan Singh. Sr.Executive(HR)
3
INDEX PROJECT TITTLE ACKNOELEDGEMENT
COMPANY INTRODUCTION About TI Automotives
World Organization Structure Product
Overview Environment quality INDUSTRY
OVERVIEW PROJECT INTRODUCTION Objective Of
Training Objective Of Project Introduction To
Project ANALYSIS AND FINDINGS CONCLUSION AND
RECOMMENDATIONS ANNEXURE
4
ACKNOLEDGEMENT I am very grateful to all under
whom I completed my summer training .I would like
to give my heartiest thanks to Mr. Mohan Singh
who give me opportunities (letter to join as
trainee) to do training at Bundy India Limited.
I would like to express my deep gratitude to
Mr. Ravi Verma (project guide) at Bundy India
Limited for their keen interest, valuable
guidance and constant encouragement during the
course of my accomplishment of this project. I am
very grateful to them for introducing me to the
technicalities and explaining the subtleties of
the project and process flow of the plant.
5
COMPANY INTRODUCTION
6
TI Automotive has maintained the position of a
premier supplier to an ever-changing global
market since 1922, with advances in small
diameter steel tube manufacture, design and
fabrication Technology and innovation have always
been our driving force, offering far more than
just tubing expertise to the automotive
industry. Bundy double wall tubing is
manufactured from a low carbon, tight tolerance
continuous strip of copper plated cold rolled
steel, double wrapped (through 720 degrees) and
brazed in a controlled atmosphere to form a
double-walled tube.
7
COMPANY BACKGROUND INFORMATION
TI Automotive is the world's
leading supplier of fluid storage, transfer and
delivery systems including brake, fuel and air
conditioning applications. FOUNDED
TI Automotive Ltd was formed as an independent
company in 2001 in England. Following the merger
of TI Group with Smiths Industries in December
2000, TI Group Automotive Systems became a
division within Smiths Group plc. In July 2001,
the automotive division demerged from Smiths
Group. EMPLOYEES TI Automotive
has more than 16,000 employees in more than 100
facilities worldwide. BUSINESS DIVISIONS
TI Automotive is divided into two
major divisions. The Fuel Systems group has
approximately 40 of company sales and the Fluid
Carrying Systems group has 60. GROWTH
CHORONOLGY TI Automotive's
roots are in the remarkable transformation of TI
Group plc from a declining British company in
1986 to a thriving global business by 2000. TI
Group, which originated as Tube Investments Ltd
in Birmingham, England in 1919, grew its
automotive business with these major
acquisitions
8
PRODUCT OVERVIEW
Our core product offerings focus on the design,
development and manufacture of multi-layer blow
molded plastic fuel tanks with integrated fuel
delivery module assemblies, including turbine or
gerotor pumps, electronic control modules, sensor
units and fill and vapor control valves.
Complimenting these leading edge complex fuel
tank systems are TI Automotive's rigid and
flexible fuel and brake lines, each available
with a comprehensive range of coating
applications and unique connector technology.
Our total systems solutions provide the world's
automotive manufacturers with a filler neck fuel
rail package that is designed to optimize cost,
space, weight and fitment parameters whilst
surpassing safety and emissions requirements.
Additionally, TI Automotive offers world class
air conditioning module assemblies. Steel and
aluminum accumulators and unitized receiver
dryers are integrated with rigid and flexible
hose assemblies to provide efficient and optimum
performance in this high temperature environment.
9
Fluid Carrying Systems
Our routing expertise comes into its
own in the crowded vehicle underbody. Brake and
fuel line bundles, designed to optimize space and
maximize fitment speed, save valuable assembly
time. Supplied on a just-in-time or
sequence-delivery basis, we provide simple
inventory. Control and reduced assembly-line
congestion.

10
Brake Fuel Products -
TI Automotive provides a brake and fuel solution
for each customer application. Our tubular
products include rigid brake and fuel lines,
flexible fuel lines, and high-pressure diesel
products designed to meet a variety of customer
needs. Corrugated monoand multi-layer tubes and
assemblies complete the portfolio for fuel-vapor
systems. A comprehensive range of coatings, which
exceed corrosion and abrasion protection
standards, enhances product quality and
durability

11
Air Conditioning Tube Hose Assemblies-

Ever-changing emission, fuel efficiency, and cost
requirements demand enhancement of current
air-conditioning systems as well as innovation in
alternate refrigerant technology. As a driving
force for cost-effective materials, design, and
processes for the mobile air conditioning loop,
TI Automotive continues to set standards within
the industry. Our combination of coupling,
bending, and connection technology enables us to
meet our customers unique needs for quick
connectors, in-line heat exchangers, and
high-pressure couplings.
12
Heater Radiator Hose Systems
We
offer a wide range of hose constructions and
diameters to match our customers needs,
including high-temperature requirements.
Manufacturing capabilities include formed,
coupled hoses with tube or quick connectors and
pre-positioned clamps (mechanical/adhesive).

13
Other Automotive Products
Our
commitment to lean manufacturing has pushed our
connector technology to the forefront of the
automotive industry, and TI Automotive produces
more quick connects than anyone else in the
world. From high-pressure quick connects to
spin-welding joints between a quick connector and
flexible tube line, we provide solutions for
every manufacturing need. In addition to meeting
the automotive industrys low-permeation
standards, our connectors make for easy
installation at the assembly line. TI Automotive
also manufactures air bag tubes and other formed
tubular products in a variety of intricate shapes
to meet our customers specifications. These
products are supplied to all tiers of the
automotive supply cha


14

• Product Quality-
• Copper Plated Double Wall
  Steel Tubing
• specifications SAE J527, ASTM A254.
• Meets automotive brake tube specifications
  worldwide
• Available in coils, straight boom lengths,
  cut-to-length, or fabricated assemblies
• Available annealed
• Some common applications include brake lines,
  high-pressure fuel injection lines, hydraulic
  line and compressor lines

Product Features Product Benefits
Double wall construction Designed to withstand high internal pressures and combat vibration fatigue
Bead free no weld flash inside or outside the tube Smooth, clean, precise I.D.
Copper finish on inside and outside of tubing Facilitates brazing tubing to fittings, stampings and other parts
Available in a wide variety of coatings. Extended corrosion protection
15

• Single Wall Low Carbon Steel Tubing
• Meets or exceeds specifications SAE J525, SAE
  J526, SAE J356A, ASTM A269, and ASTM A268. Meets
  all automotive industry standards.
• Some common applications include
• fuel supply and return lines
• vent and vacuum lines
• fuel rails
• power steering
• engine/oil coolers
• HVAC components
• Fuel filler necks
• refrigeration

Product Features Product Benefits
High grade single wall strip materials are utilized to ensure optimized physical properties Provides ease of fabrication and can be expanded, compressed, flattened, cut formed or bent into almost any shape
Most sizes available as welded, cold drawn, or annealed Enables low-cost material substitution
Available in a wide variety of coatings stainless alloys Provides a variety of low cost corrosion protection options to meet every application
Conductive Nylon O.D. coated tube, with or without nickel I.D., available Offers a replacement for many stainless steel and aluminum tubing applications
Fluid and gas carrying capabilities at medium to high pressure Provides a wide range of product capabilities
16
Coatings
Inner Sacrificial Layer Outer Barrier Layer Other Info. Meets OEM Customer Specifications
Hot Dipped Alloy Layer consisting of 95 Zinc and 5 Aluminum None Coating may be soldered. Contact TI Automotive for method description. Daimler ChryslerPS-8688 Code NZ Ford Motor CompanyESA-M1A270-A General Motors Corp.GM123M GM124M Code AG
17
PVF COATING
Inner Sacrificial Layer Outer Barrier Layer Other Info. Meets OEM Customer Specifications
Electroplated Zinc Layer PVF ( Polyvinyl Fluoride ) Paint Layer Daimler ChryslerPS-8688 Code PE Ford Motor CompanyWSK-M2P139-AESA-M21P20-A

18
Process Of Production-
1. Material
receipt 2 .Tube Cutting 3 .Deburring Air blow 4
.Swaging 5 .1st End Forming 6 .Sleeve Cutting 7
.Nut/Sleeve Insertion 8 .2nd End Forming 9
.Marking/Sleeve Location 10 .Sleeve Shrinkage 11
.Inspection/Final Air Blow 12 .CNC/Power
Bending 13 .Manual Bending 14 .Leak Testing 15
.Final Inspection 16 .Packing/Storage 17
.Dispatch
19
1 .Material Receipt
20
2 .Tube Cutting- Cut the tube with the help of
power cutter according their length
21
3 .DeburringAir Blow During they cutting process
the sharp edges are formed in the end so we
remove the sharp edges .We use deburring process
air blow for remove dart particle in tube.
22
4 .Swaging - During
the deburring process the diameter of tube
increases so we want to actual size of the
diameter of the tube we use swaging process.
23
5 .1st End Forming -
After the swaging operation we form the
first and of the tube using pressure punching
machine .pressure which is use is 70kgf/cm2
24
6.Sleeve Cutting
Some time we avoid the fuel pipe and break
pipe from heat and corrosion we use sleeve pipe
insert in the sleeve
25
7 .Nut/Sleeve Insertion-
After forming the 1st end insert the nut and
sleeve. This operation is held manually
9 .Marking/Sleeve Location Marking
the position of the sleeve in the pipe and inert
the sleeve 10 .Sleeve Shrinkage
After insertion of the sleeve .The
pipe is passes over the temperature about 140 C.
and then sleeve shrink
26
11 .Inspection/Final Air Blow
Inspection for the cut and other fault like
leakage
27
12 .CNC/Power Bending The pipe is bend with the
help of the CNC/Power bending according to their
PLANE,FEED,BEND.Pressure is required for this is
6 bar
13 .Manual Bending This operation is also done
with the help of manual bending
28
14 .Leak Testing This is for the test for leakage
in the pipe. Fill the air in the pipe then pipe
deepwater tank
15 .Final Inspection 16 .Packing/Storage 17
.Despatch
29
Environment Quality Environmental
Responsibility In order to minimize its own
impact on the environment, TI Automotive is
seeking ISO 14001 certification on a global
basis. This international standard sets criteria
to ensure that an effective environmental
management system is in place at each facility.
We monitor our environmental performance closely
and third party verification audits are conducted
annually. With these aids we can assess our
achievements and review our targets on a regular
basis. Our aim is ongoing improvement so further
developments are constantly being implemented.
All eligible TI Automotive sites are ISO 14001
certified or working toward certification. Many
of TI Automotive's products have positive
environmental impacts in terms of emissions and
noise reduction. We constantly monitor emissions
legislation on a global basis. California's
upcoming LEV II and PZEV standards are the
current driver for evaporative emissions
regulations, worldwide. These stringent standards
are likely to serve as the model, with
modifications, for future standards throughout
the world. TI Automotive is committed to helping
its customers meet LEV II, PZEV and other future
standards with innovative, cost-effective, fuel
system products.
30
Global Customer Base
TI Automotive has a supplier
partnership with every major Original Equipment
Manufacturer (OEM) in the world. TI Automotive is
able to maintain these relationships by
continually adapting as the automotive industry's
boundaries expand across the globe. Our global
customer base includes the following companies
31
BMW
Honda
Hyundai
Isuzu
Fiat

Daewoo
Ned car
Ford
PSA
General Motors
Renault
Toyota
32
BIBLIOGRAPHY-
www.Tiautomotive.com
33
Thanks.No questions plzzz.