INDUSTRIAL TRAINING

REPORT
ON

VARROC ENGINEERING
Pvt. Ltd
1
 INDUSTRIAL TRAINING REPORT
On

VARROC ENGINEERING Pvt. Ltd

Submitted By

VINAY . R . MARTA
Submitted To

Department Of Mechancal Engineering,

Government Polytechnic, Solapur.
Under The Guidance Of
Prof. A. S. KAPPIKERI
Affiliated To

Maharashtra State Board Of Technical

Education, Mumbai.
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 CERTIFICATE

This is to certify that, Mr. Vinay R. Marta

Enrollment No. 1900150532 of Fifth Semester of Diploma in
Mechanical engineering of Institute Government Polytechnic,
Solapur (Code: 0015) has completed the Industrial Training
satisfactorily under my supervision and guidance for the academic
year 2021-2022 as prescribed in the curriculum.

Prof. A. S. Kappikeri Prof . C.B. Shete

Mentor H.O.D

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 INDEX
Sr. No CONTENT Page. No
1 Acknowledgement 5
2 Introduction to company 6
3 History of Varroc Engineering Pvt. Ltd. 8
4 Vision of the company 10
5 Missions of the company 11
6 Company's profile 12
7 Quality policy & Saftey policy 13
8 Machines used in plant 15
8 Products 28
9 Manufacturing process 31
10 Joint Ventures & Subsidiaries 37
11 Milestones Achieved 38
12 Conclusion 39
13 References 39

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 Acknowledgement

We wish to express our profound and sincere gratitude to our

mentor Prof. A. S. Kappikeri, who guided us into the intricacies of
this industrial training non-chalantly with matchless magnanimity.
We are indebted to his constant encouragement, co-operation and
help. It was his enthusiastic support that helped us in overcoming
the various obstacles in this training.
We would also like to express our thankfulness to our beloved
Principal Prof. Hunasimarad S.K our H.O.D. Prof. C. B. Shete and
other faculty members of our Mechanical Engineering Department
for extending their support and motivation
Finally, we would be failing in our duty, if we don’t acknowledge
the cooperation rendered during various stages of this micro-
project by our group members.
Thank you ….......!

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 INTRODUCTION
“Tree cannot touch the skies, but certainly can have branches.”
Varroc Group too believes in this axiom, and has strong footholds
in Polymer, Electrical, and Metallic Divisions and exists in all
important auras of Automobile sector.
Now, Varroc Group has ventured into the field of automotive
components & sub assemblies of 2, 3, and 4 wheelers in domestic
and overseas market with an objective to become the preferred
quality supplier across the globe.
The Varroc Group manufactures and markets a highly
diversified portfolio of automotive components and sub-
assemblies for two wheelers, three wheelers, and four wheelers,
for sale in the domestic market as well as overseas.
The Group is structured into two separate entities: Varroc
Polymers, and Varroc Engineering, as names suggest, manufacture
polymer based and engineering based components (electrical,
electronic and mechanical) respectively.
Varroc’s rate of growth has consistently outpaced the industry
growth rate as a whole. This consistent high growth has been
fueled by their focus on operating efficiency and product quality.
"The Varroc Group has built-up a significant presence in quality
automotive components and sub-assemblies for 2, 3, and 4
wheelers in the domestic as well as the overseas markets."

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 ABOUT METTALIC DEPARTMENT
The metallic division is the primary growth thrust area for the
Group as a whole, products currently manufactured include engine
values, hot, warm and cold forged parts, and catalytic converters.
The Division operates through six plants in India & Europe.
As in the case of all cutting edge manufacturing the core
strength of the Division lies not in the manufacturing ability but in
its product Development and Engineering expertise. This enables
us to save cot and time from the receipt of enquiry to the
commencement of production. This provides a significant
differentiator compared to the other manufactures. For example,
our forging simulation software eliminates the need for costly shop
trails of new dies and also enables us to provide an optimum weight
of the forged part. It is thus possible to quote more competitive
prices without sacrificing profitability wherever fully finished parts
are supplied, the optimized forging weight facilitates reduced cycle
times on sub sequent operations again resulting in cost saving.
“The Engineering Centre for supporting European operations is a
group of 10 dedicated engineers who create two to three 3-D
models par day thus reducing product development time
drastically.”
- Mr. Ram Parthasarathy
Group Sr. Vice President,
Metallic Division.
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 HISTORY OF VARROC
ENGINEERING
Varroc was established by Tarang Jain in 1990, in Aurangabad,
India with the commencement of company's polymer division.
Between 1992 and 1998, the company focused on product
diversification and capacity expansion and started
its electrical and metallic division. Varroc started more polymer
manufacturing facilities in 1997 in Pune and Aurangabad.
In 2001, Varroc expanded its development capabilities by
collaborating with Mitsuba Corporation, a Japanese manufacturer
of automobile parts. The company collaborated
with Brussels based materials technology company, Umicore, in
2005 and started production of automotive catalytic converter.
Between 2007 and 2010, Varroc acquired IMES, Poland and Italy to
strengthen forging business in European markets, off-road and oil
drilling industry. The company also invested in manufacturing
capability for polymers in National Capital Region to cater
to OEMs in North India.
In 2011, Varroc acquired European two wheeler lighting
organization Tri.O.M. S.p.A. including its R&D center. In 2012,
Varroc's turnover crossed USD 1 billion mark with acquisition
of Visteon's Lighting Business along with its two R&D centers.
Varroc established its eighth polymer plant in Pithampur, Indore, in
2012, which caters to Volvo, Eicher and Mahindra Two
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Wheelers. Another polymer plant was established
in Bengaluru that caters to HMSI and passenger car segment.
The company also invested in design and set up of the 10th
polymer plant at Chennai to supply Yamaha Motor Company.
In 2015, Varroc partnered with UK Based manufacturer and
supplier Scorpion Automotive Ltd to provide security based
products for two wheelers.

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 Vision

To be an INR 200 billion supplier of innovative solutions for

transportation and allied industries

 Core business sectors to be exterior lighting and two-

wheelers mobility emission technologies

To be the fastest growing player in our core sectors

To be in leadership positions in both our core business

sectors

Providing an environment, conductive to the

development, growth and satisfaction of employees while
fulfilling their reasonable aspirations

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 MISSION
TO BRING LEADING-EDGE TECHNOLOGIES TO THE MAINSTREAM
MARKET WITH HIGH QUALITY AND COST COMPETITIVE
SOLUTIONS:

 By delivering customized solution with superior

servicesWith speed, agility and creativity.

And fostering an environment that empowers

employees and encourages the pursuit of excellence.

Contributing to the well being of the society and

conducting ourselves as a responsible corporate
citizen known for integrity and ethics.

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 COMPANY’S PROFILE

Name Varroc Engineering Pvt. Ltd

Address Varroc Engineering Pvt. Ltd.
VEPL – V
L – 6/2, MIDC Industrial Area,
Waluj, Aurangabad – 431136.
Maharashtra, India
Year of Establishment 1990
Land 45000 sq. m
Standards ISO 9001-2000 Certified
ISO /TS 16949:2001
ISO 14001 Certification
Products Automobile parts
No.of . Employees >1000
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QUALITY & SAFTEY POLICY

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14
MACHINES USED IN COMPANY

 LATHE

 CNC BORING MACHINE

 CNC PLASMA CUTTING MACHINE

 TAPPET END GRINDING MACHINE

 INDUCTION HARDENING MACHINE

 PLASMA WELDING MACHINE

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 LATHE

Every manufacturing plant needs a lathe machine. It is called the

mother of all machines. It is a tool that is used to provide specific
design, shape or appearance to the workpiece. The lathe machine
has a rotating part as its component which helps to carry out
various operations over the workpiece such as grooving, turning,
knocking, etc. Rack and pinion systems plays an equally important
role in creating intermediary products for automobiles.

PARTS OF ALL GEARED LATHE MACHINE

 Bed
 Headstock & Headstock Spindle
 Tailstock & Carriage
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ADVANTAGES OF LATHE MACHINE
 It is suitable for easily executing high end tasks and
powerful machining jobs.
 It provides total freedom for effectively cutting and
drilling tough metals.
 It provides top quality results has applications in
various heavy industries.
OPERATIONS PERFORMED
 Turning & Facing
 Knurling & Chamfering
 Thread cutting & grooving

SPECIFICATIONS

Machine All geared lathe machine

Manufactured by Banka
Height of center 175mm
Spindle bore 50mm
Bed length 6 feet
Spindle speed 1535rpm
Bed width 242mm
Motor 3hp

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 CNC BORING MACHINE

A CNC boring mill transforms raw material into a finished

model by subtraction. The machine uses a cylindrical
cutting tool that can rotate in different directions and
move on several axes. It also has the ability to create a
wide range of shapes, slots, holes and other cuts.

PARTS OF CNC BORING MACHINE

 Bed
 Headstock supporting column
 End supporting column
 Saddle, Table & Boring bars
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 ADVANTAGES OF CNC BORING MACHINE
 The ability to produce a large quantity of machined
parts in less time
 The ability to manufacture large format machined
parts
 Reduction of tool deflection

OPERATIONS PERFORMED
 Reaming & Recessing

SPECIFICATIONS
Manufactured by PAMA
CNC Siemens 840 D
X Travel 9000 mm
Y Travel 4000 mm
Z Travel 2000 mm
Table length and width 1500 x 3000 mm
Spindle taper ISO 60
Spindle diameter 203.2 mm
Max. spindle speed 660 rpm
Spindle motor power 60 kW

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 CNC PLASMA CUTTING
MACHINE

Plasma cutting is a process in which electrically conductive

materials are cut through by means of an accelerated jet
of hot plasma. Typical materials that can be cut with a
plasma torch are steel, stainless steel, aluminium, brass,
copper and other conductive metals. Plasma cutting is
widely used in manufacturing, automotive repair and
restoration, industrial construction, salvage and
scrapping. Plasma cutting - Conductive gas with a
temperature of up to 30,000°C makes plasma cutting so
special.

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PARTS OF CNC PLASMA CUTTING MACHINE
 Plasma power source & arc starting console
 Torch assembly & gas supply
 Cooling system & an electrically conductive
workpeice

ADVANTAGES OF CNC PLASMA CUTTING MACHINE

 Able to cut all conductive materials
 Best way to cut medium thickness stainless steel
 Able to provide high precision and repeatability
SPECIFICATIONS
Manufactured by Altlas Machines
Model AMI-PTT3015
Working area 3000x1500 mm
Gross power 20Kw
Power source Hypertherm
Oxygen pressure AIR COMPRESSOR
– 4kw
Cutting speed 13-15m/min
Max cutting thickness 20mm M. steel
Max cutting length 3000-4000mm
Design software AutoCad, CAXA
Nesting software Fastcam
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 CNC TAPPET END GRINDING
MACHINE

This is a pendulum type machine wherein the valve moves

over a grinding wheel capable of stock removal of up to
2mm in one stroke. Used for removal of extra material on
engine valve and also used for finishing of the valve
surface

ADVANTAGES OF CNC TAPPET END GRINDING MACHINE

 Versatility. Surface grinding can be performed on a
wide variety of materials, including material that are
abrasive or hard, and metallic or non-metallic
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  Accuracy. Surface grinding can be performed with
high degree of accuracy

 High quality finishing

SPECIFICATIONS
Manufactured by ETA
Power source Electrical
Valve length 8 – 150 mm
Valve steam 5-8 mm
diameter
Valve head diameter 25-40 mm
Grinding wheel 400 mm
diameter

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 INDUCTION HARDENING
MACHINE

Induction hardening is a process used for the surface

hardening of steel and other alloy components. The parts
to be heat treated are placed inside a copper coil and then
heated above their transformation temperature by
applying an alternating current to the coil. Heating coil
into a water quench, the outer skin can be heated,
quenched, and hardened without affecting its core.

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ADVANTAGES OF INDUCTION HARDENING MACHINE
 Fast localized heating reduces the processing time to
seconds
 Reduced heat and quench times
 Compared with carburizing, induction hardening
eliminates copper masking, packing, straightening
and extra machining operations.
SPECIFICATIONS
Manufactured by Induction Equipment
India Pvt. Ltd.
Voltage 220- 380 V
Thickness 10- 20 mm
Phase Single
Frequency 50- 60 Hz

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 PLASMA WELDING MACHINE

Plasma arc welding (PAW) is an arc welding process very

similar to TIG welding as the arc is formed between a
pointed tungsten electrode and the workpiece . Plasma
welding machines melt areas with an arc and then use a
high-velocity, high-temperature ionized gas to make
welds. The process of plasma welding is used to bring
better control to the arc welding process in lower current
ranges.

PARTS OF PLASMA WELDING MACHINE

 Power supply & plasma welding torch
 Water re- circulator
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  Tungsten electrode & sheilding gas
 Plasma gas & torch accessory kit
 Filler material
ADVANTAGES OF PLSMA WELDING
 Control and quality produced in the part being
welded.
 The torch design allows for better control of the arc,
as well as higher tolerance for in torch standoff
distance
 Welds are typically cleaner and smoother when using
the PAW process

SPECIFICATIONS
Model PW 100
SUPPLY (V) 220 +/- 10%
Phase / Freq. (Hz) 50 – 60
Power factor 0.95
Max current 100
Input KW 3.8
Display Digital
Dimensions W x L x H 490 x 660 x670
(mm)
Plasma welding torch 200/ 400 Amp

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 PRODUCTS
ENGINE VALVE:
Engine valves are mechanical components used in
internal combustion engines to allow or restrict the
flow of fluid or gas to and from the combustion
chambers or cylinders during engine operation.
There are 2 types of
valve
 Inlet valve
 Exhaust valve
Valves have three
parts
 Head
 Stem
 Groove

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CRANK PIN :
A crankpin is a mechanical device in an engine which
connects the crankshaft to the connecting rod for
each cylinder. It has a cylindrical surface, to allow the
crankpin to rotate relative to the "big end" of the
connecting rod. The most common configuration is
for a crankpin to serve one cylinder. Crankpins
transfer up-and-down motion between the
crankshaft and connecting rod. Connecting rods
typically have two-piece crankpin bearings for
connecting the lower end of the rod to a crankpin of
a crankshaft.

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CAMSHAFTS:
A camshaft is a rotating object— usually made of
metal— that contains pointed cams, which converts
rotational motion to reciprocal motion. Camshafts
are used in internal combustion engines (to operate
the intake and exhaust valves), mechanically
controlled ignition systems and early electric motor
speed controllers. Camshafts in automobiles are
made from steel or cast iron, and are a key factor in
determining the RPM range of an engine's power
band.

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MANUFACTURING PROCESS OF ENIGINE
VALVE

There are 3 steps included in manufacturing

engine valves
 Design
 Production
 Inspection & Quality control

Design
Very skilled professionals engineers and designers
come together for R&D, designing of engine valve.
For designing purpose they use ‘Catia’ ‘Valvetrain
Module’ and ‘Virtual Engine’. This software provides
maximum freedom in valvetrain modeling to support
all kinds of valvetrain design. After completion of
design, production process starts.

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Designing of engine valve
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 Production Process

Material :
Austenitic steel,
Martensitic steel for the valve stem.

Bar Shearing:
Bar shearing is a process in which steel bars are
passed through a die or shear blades, cutting them
mechanically. This mechanical shearing action
breaks the bar in desired size and length. After this
process the workpeice (bar) is sent to its next step.

Friction Welding :
Friction welding is a solid state bonding process that
produces high integrity, full contact joints. By
rotating one work piece relative to another, under a
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compressive axle force, the
friction generated between
the two surfaces produces
heat, causing the interface
material to plasticise and get
welded.

UPSET FORGING:
Upset Forging is accomplished by holding pre-heated
material between grooved dies. Pressure is then
applied to the end of the bar in the direction of its
axis. The Heading Tool upsets the end of the bar by
displacing the heated metal within a cavity. Bar takes
raw shape of the valve.

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 After the process of upset forging the raw valve is sent for
seat depositing process. Seat depositing is nothing but to
deposit metallic material at the corner of seat to maintain
the airtightness in the engine cylinder. After the process
of seat deposit process the raw valve is sent in machining
line, with the help of auto loading machine, known as bowl
feeder.

From here the machining process starts.

ROUGH END GRINDING :

In rough end grinding process the end surface of the valve
is made smooth by grinding machine. This technique can
be best compared to the coarse filing of surfaces since a
lot of excess material is removed.
GROOVE GRINDING :
The valve is loaded on blades in centerless grinding
machine. There is a rigid clamping which helps valve to be
stable while blades perform their work, hence groove is
formed.
TURNING OF HEAD DIAMETER & FACING:
In this process the excess amount of metallic particle is
removed and finished at the head diameter of valve, as
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well as the excess amount of metallic particle is removed
from the margin and finished curve is made at the margin
of head.
INDUCTION HARDENING :
Induction hardening is process used for the surface
hardening of the valve. The valve is placed in the
induction hardening machine which consists of copper coil
and heated above their transformation temperature by
applying an alternate current to the coil.
FINISH END GRINDING :
In this process the valve in mounted on the tappet end
grinding machine. There is clamping which makes valve
stable while grinding. Then the grinding wheel rotates and
as a result the end of the valve gets smooth finish and
excess material is removed.
AUTO INSPECTION :
After the manufacturing process the ready valve is snet
for inspection. Where a camera autonomously scans the
valve under test for both catastrophic failure and quality
defects. After the inspection the valves are set in a tray by
robotic arm and ready packed.

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 JOINT VENTURE & SUBSIDIARIES

 In 2001, Varroc expanded its development capabilities by

collaborating with Mitsuba Corporation, a Japanese
manufacturer of automobile parts.

 The company collaborated with Brussels based materials

technology company, Umicore, in 2005 and started
production of automotive catalytic converter.

 Between 2007 and 2010, Varroc acquired IMES, Poland

and Italy to strengthen forging business in European
markets, off-road and oil drilling industry.

 The company also invested in manufacturing capability for

polymers in National Capital Region to cater to OEMs in
North India.

 The company also invested in design and set up of the

10th polymer plant at Chennai to supply Yamaha Motor
Company.

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 MILESTONES
 In 2016, Emerging Manufacturing Giant citation honour
by Devendra Fadnavis, Chief Minister of Maharashtra,
India on behalf of Indian Merchants' Chamber.
 India Automotive Lighting Technology Innovation
Leadership Award” at the Frost & Sullivan’s GIL 2016: India
Awards.
 Environmental Youth of the Year award 2016 for
implementing green initiatives from Clean & Green India
jointly with SingEX, Singapore and Franchise India.
 Kaizen Award in Innovative Kaizen Category during 26th
CII–TPM Club National Kaizen Conference Cum
Competition held at New Delhi.
 In 2015, Best Supplier Award 2015 from Danfoss for best
performance in quality and delivery to multiple Danfoss
global locations & proactive planning for keeping
commitments
 New Product Development Award by HMSI
 In 2013, Tarang Jain received Forbes Next Generation
Entrepreneur award.

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 CONCLUSION
After the completion of industrial training we enhanced
competencies & competitiveness in our respective area of
specialization. We tried to relate the experience in the workplace
with knowledge learned in the institute & applied the knowledge
on the job under supervision. Here, we gained the experience &
knowledge that can be used for suitable job without delay after
studies. We learned to hone soft skills appropriate to the work
environment. Also get improvised in communication skills. We
assessed career ability, knowledge & confidence as well as
enhanced our marketability to be more competitive. With
experience, knowledge & skills acquired during industrial
training we will be better prepared to face working world.

REFERENCE
 https://varroc.com/
 https://youtu.be/Raoo6cMGTFc
 https://youtube.com/c/VarrocGlobal
 https://en.m.wikipedia.org/wiki/Varroc

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