A PROJECT REPORT

ON
Implementation of Spotting on A.C Evaporator
Mounting Bracket

By
C.Chaitran
(11K41A0311)
MECHANICAL ENGINEERING

By
T.Raviteja
(11K41A0353)
MECHANICAL ENGINEERING

S.R ENGINEERING COLLEGE.

HASANPARTHY, (DIST) WARANGAL.

ABSTRACT
In Mahindra & Mahindra A.F.S zaheerabad, L.C.Vs , Boleros , and
other utility vehicles are manufactured.
In these boleros there are A.C variants,In these variants,the A.C
evaporator is mounted inside the cabin using a bracket.
Previously, the bracket is attached to the cabin using MIG
welding. In this case gaps are formed between the bracket and
cabin, it lead to failure in the joint in such a way that the bracket
is detached from the cabin even it was pulled manually.
We studied the various processes which helps in improving the
strength of the joint. Then the work content of each activity is
studied and then calculated with the help of MOST. The MOST is a
technique which helps in quantifying out work. Then the
complete work content in attaching the bracket is determined.
Depending upon the production requirement in body shop, the
machinery required is calculated

COMPANY OVERVIEW
TYPE

Privately held company (BSE : 500520)

INDUSTRY

Conglomerate

YEAR OF ESTABLISHMENT

1945

HEAD QUARTERS

Mumbai, Maharashtra ,India

AREA SERVED

World wide

KEY PEOPLE

Anand Mahindra (Chairman)

Vineeth naayra (VC & CEO)

PRODUCTS

Aerospace ,after market, agribusiness,

automotive, etc

REVENUE

US $ 16.8 billion

PROFIT

Rs. 3,769.79corers (approx)

SUBSIDIARIES

Mahindra & Mahindra, Mahindra Aerospace,

EMPLOYEES

155,000 (approx)

PARENT

Mahindra group

WEBSITE

www.mahindra.com

etc

DIVISIONS IN A.F.S PLANT

PAINT SHOP
ASSEMBLY LINE
UTILITY VEHICLE LINE
BODYSHOP LINE
L.C.V LINE
ALFA LINE

OVERVIEW OF BODYSHOP
In A.F.S plant, Body shop consists two main production lines -1. Load king
2. UV Line

Body shop is also supported by other functions like Manufacturing

Engineering., Maintenance, Part
Development, HR & ER, Administration, PD & Plant Vehicle Team.
Manufacturing activity of Body shop is mainly Spot welding, Co2 welding,
brazing& Metal finishing.
Body shop receives components from Supply module & dispatches body
shells to Paint shop.
Body Shop has following types of major machines / equipments
1. Spot welding machines
2. CO2 welding machines
3. Brazing sets
4. Fixtures

PROCESSES CARRIED OUT IN

BODYSHOP

Spot Welding
MIG Welding
Brazing
Nut Welding
Grinding
Buffering
Sandering

PROJECT
IMPLEMENTATION OF SPOTTING ON A.C
EVAPORATOR MOUNTING BRACKET
In UV production line of the body shop, the A.C
variant BOLEROs are processed, In those variants
the A.C Evaporator is mounted on a bracket.
The bracket is attached to the body by MIG welding.
But the strength of the weld of the weld was very
low.
Our project was to MOUNT THE BRACKET WITH OUT
ANY DAMAGES.

Problem Statement
Two
brackets are
welded as T-joint
for
evaporator
mounting.
Attach the evaporator mounting bracket to the
body
avoiding deformations

Use of MIG welding to attach the

bracket to the cabin

MIG welding resulted in the failure of Mounting

Bracket, gaps are formed between the cabin
and the bracket. This resulted in breakage of
bracket.
The welding is such a failure that the bracket
can be detached manually
Hence use of MIG welding resulted in failure.

Use of MIG welding to attach the

bracket to the cabin
MIG welding resulted in the failure of Mounting Bracket, gaps
are formed between the cabin and the bracket. This resulted
in breakage of bracket.
The welding is such a failure that the bracket can be
detached manually
Hence use of MIG welding resulted in failure.

Gaps formed between the bracket and body is shown in

above photograph

Use of Spot welding to attach the

bracket to the cabin
The introduced alternate was Spot welding.
The spot welding is used in the brackets as the thickness of
the
metal is below 2mm
The use of spot welding gave better results than that of MIG
welding, but could not provide adequate strength by use of
spot welding alone
The spot welding is done to the bracket with cabin without
giving a proper support lead to failure in spot welding

spot welding

FAILURE IN SPOT WELDING

The use of spot welding gave better results than that

of MIG welding, but could not provide adequate
strength by use of only spot welding..The spot welding
on the sheet with out proper support did not give
required strength.and lead to deformation. The spot
welding is done to the bracket with cabin without
giving a proper support. This lead to failure in spot
welding

SPOTTING GUAGE
The failure in spot welding of bracket lead to an initiation of
an alternative.
As it was found that the failure in spot welding is due to lack
of support to the bracket at the time of welding.
Hence it was minimized by preparing a temporary support at
the time of welding.
This is done by designing a gauge to support the bracket. It
is termed as SPOTTING GUAGE

spotting gauge

SPOT WELDING BY SPOTTING

GAUGE

The Spotting gauge is used to hold the bracket with

cabin and the spot welding is done. This process gave
adequate strength to the bracket in holding with the
cabin

Spot welding using Spotting gauge

The Spotting gauge is used to hold the bracket with
cabin and the spot welding is done. This process gave
adequate strength to the bracket in holding with the
cabin

Spot welding using spotting gauge

Evaporator mounting bracket welded

using Spotting Gauge

By this process proper results are obtained and the failure is

minimized and the standards are maintained

Evaporator mounting bracket welded

using Spotting Gauge
The process of welding the bracket to the body
using spotting gauge, the chances of failures are
minimized almost to zero and the standards are
maintained.

Evaporator mounting bracket attached to the

body by SPOT welding with the help of a spotting
gauge.

Thank you