_industrial Training _report_format Mu (1) (1) Final Report

INDUSTRIAL TRAINING REPORT METAL CASTING Submitted in partial fulfillment of the Requirements for the award of

Degree of Bachelor of Technology in Mechanical Engineering

Submitted By : Name: University Roll No.

Anish Kumar EN16EE301011

Department of Mechanical Engineering FACULTY OF ENGINEERING MEDI-CAPS UNIVERSITY, INDORE- 453331

Report Approval The Industrial Training Report entitled “METAL CASTING” is hereby approved as a creditable study of an engineering subject carried out and presented in a manner satisfactory to warrant its acceptance as prerequisite for the Degree for which it has been submitted. It is to be understood that by this approval the undersigned do not endorse or approved any statement made, opinion expressed, or conclusion drawn there in; but approve the “Industrial Training Report” only for the purpose for which it has been submitted.

Internal Examiner Name: Designation Affiliation

External Examiner Name: Designation Affiliation

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DECLARATION I hereby declare that the Industrial Training Report entitled ("METAL CASTING") is an authentic record of my own work as requirements of Industrial Training during the period from 08/07/19 to 31/07/19 in the Department of Metal Casting , Porwal Auto Components Ltd. , Sector-1, Industrial Area, Pithampur .

Anish Kumar EN16EE301011 Date:

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CERTIFICATE

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ACKNOWLEDGEMENT From 8th July 2019 to 31th July 2019,I had the privilege and pleasure of joining a team of dedicated professional from PORWAL AUTO COMPONENTS LTD. The internship opportunity I had was a great chance for learning and professional development. Therefore , I consider myself as a very lucky indivisual as I was provided with an opportunity to be a part of it . I am also greatful for having a chance to meet so many wonderful people and professionals who led me through this internship period. I express my deepest thanks to Mr. Kapil Sharma Sir (Supply Chain Management), Mr. Shughosh Mani (HR) & R K Sahu Sir (HRM Manager) for taking part in useful decision and giving necessary advices and guidance therefore I would like to acknowledge their contributions gratefully. I would also like to acknowledge and express gratitude to Mr. Shughosh Mani Sir for introducing me to the company for internship and giving me continuous support throughout the course of internship.

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Table of content Report Approval………………………………………………………i Declaration……………………………………………………………iii Certificate………………………………………………….………….iv Acknowledgment……………………………………………………. v List of Content………………………………………………………..vi List of figures…………………………………………………………vii List of tables………………………………………………………….vii 1. 2. 3. 4. 5. 6. 7. 8. 9.

Introduction……..………………………………………………1 History of Porwal……….………………………………………1 Number of Departments………..………………………………1 Introduction of Casting………………………………………...2 Sand casting & testing………………………………………….2-8 Moulding machine………………………………………………9 Types of casting………………………………………………...10 Terminology…………………………………………………….11 Pattern…………………………………………………………..12 A. Single piece pattern……………………………………….12 B. Split pattern or two piece pattern………………………..13 C. Cope and drag pattern……………………………………13 D. Match plate pattern……………………………………….14

10. Cores……….……………………………………………………15-17 11. Furnace………………………………………………………….18 12. Pouring………………………………………………………….19 13. Shakeout machine……………………………………………...20 14. Material separation…………………………………………….21 15. Defects…………………………………………………………...22-24 16. Testing of material……………………………………………..24-25 17. Conclusion………………………………………………………27 18. Bibliography……………………………………………………28

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List of figures Figure 1 - Sand gating system & Mould cavity Figure 2 - Brusting strength tester Figure 3 - Sieve tester Figure 4 - Universal sand strength testing machine Figure 5 - Industation hardness tester Figure 6 - Moulding machine Figure 7 - Core piece Figure 8 - Electric furnance Figure 9 - Rockwell hardness machine Figure 10 - Plant layout

List of tables

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1. Introduction Porwal Auto Components Ltd. was incorporated in the year 1992 as an ancillary to M/s Eicher Motors Limited now VE Commercial Vehicles Ltd. (A Volvo Group and Eicher Motors joint venture). PACL has registered impressive growth and has established itself as a trusted supplier of Quality Castings and gained recognition from its customers for Outstanding Contribution to Parts Development and Supply Chain Management Our Quality Management System is ISO 9001:2008 and ISO/TS 16949:2009 certified by TUV/NORD, also has RDSO and approved by Integral Coach Factory to supply steel, S.G, Grey Iron casting and component for Indian Railway and plan to get certification for Environment, Health and safety ISO 14001:2004 and OHSAS 18001:2007. Our mission is to deliver products as per the requirements of our customers on time every time. Our aim is to be prefered supplier in the castings technology on the global front, while being accountable to all our stakeholders.

2. HISTORY OF PORWAL Porwal Auto Components Ltd. was in incorporated in the year 1992 and commenced production in the year 1995. The company is engaged in manufacturing and marketing of S.G. (Ductile) Iron, Grey Cast Iron and Steel Castings and Components for the Automobile, Engineering & Railway Applications.

3. Number of Departments 1. 2. 3. 4. 5. 6. 7. 8. 9.

Sand shop Pattern shop Core shop Casting Moulding & Pouring Furnace Lab Heat treatment Inspection

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4. Introduction of Casting Casting is one of the earliest metal-shaping method known to human beings. It generally means pouring molten metal into a refractory mould with cavity of the shape to be made, and allowing it to solidify. When solidified, the desired metal objects is taken out from the refractory mould either by breaking the mould or by taking the apart. The solidified object is called casting. This process is called casting.

5. Sand Casting Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via a sand casting process. Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand. Sand casting is one of the most popular and simplest types of casting, and has been used for centuries. Sand casting allows for smaller batches than permanent mold casting and at a very reasonable cost. Not only does this method allow manufacturers to create products at a low cost, but there are other benefits to sand casting, such as very smallsize operations. From castings that fit in the palm of your hand to train beds (one casting can create the entire bed for one rail car), it can all be done with sand casting. Sand casting also allows most metals to be cast depending on the type of sand used for the molds. Sand casting requires a lead time of days, or even weeks sometimes, for production at high output rates (1–20 pieces/hr.-mold) and is unsurpassed for large-part production. Green (moist) sand has almost no part weight limit, whereas dry sand has a practical part mass limit of 2,300–2,700 kg (5,100–6,000 lb.). Minimum part weight ranges from 0.075–0.1 kg (0.17– 0.22 lb.). The sand is bonded together using clays, chemical binders, or polymerized oils (such as motor oil). Sand can be recycled many times in most operations and requires little maintenance.

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BASIC PROCESS There are six steps in this process: 1. Place a pattern in sand to create a mold. 2. Incorporate the pattern and sand in a gating system. 3. Remove the pattern. 4. Fill the mold cavity with molten metal. 5. Allow the metal to cool. 6. Break away the sand mold and remove the casting

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SAND TESTING The moulding sand after it is prepared should be properly tested to see that require properties are achieved. Tests are conducted on a sample of the standard sand. The moulding sand should be prepared exactly as it is done in the shop on the standard equipment and then carefully enclosed in a container to safeguard its moisture content. Sand tests indicate the moulding sand performance and help the foundry men in controlling the properties of moulding sands. Sand testing controls the moulding sand properties through the control of its composition. The following are the various types of sand control tests: 1. Moisture content test 2. Clay content test 3. Grain fitness test 4. Permeability test 5. Strength test 6. Mould hardness test

Moisture content test: Moisture is the property of the moulding sand it is defined as the amount of water present in the moulding sand. Low moisture content in the moulding sand does not develop strength properties. High moisture content decreases permeability.

Procedures are: 1. 20 to 50 gms of prepared sand is placed in the pan and is heated by an infrared heater bulb for 2 to 3 minutes. 2. The moisture in the moulding sand is thus evaporated. 3. Moulding sand is taken out of the pan and reweighed. 4. The percentage of moisture can be calculated from the difference in the weights, of the original moist and the consequently dried sand samples.

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Percentage of moisture content = (W1-W2)/(W1) % Where, W1- Weight of the sand before drying, W2- Weight of the sand after drying.

Clay content test: influences strength, permeability and other moulding properties. It is responsible for bonding sand particles together.

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Procedures are: 1. Small quantity of prepared moulding sand was dried 2. Separate 50gms of dry moulding sand and transfer wash bottle. 3. Add 475cc of distilled water + 25cc of a 3%NaOH. 4. Agitate this mixture about 10 minutes with the help of sand stirrer. 5. Fill the wash bottle with water up to the marker. 6. After the sand etc., has settled for about 10 minutes, Siphon out the water from the wash bottle. 7. Dry the settled down sand. 8. The clay content can be determined from the difference in weights of the initial and final sand samples. Percentage of clay content = (W1-W2)/(W1) * 100 Where, W1-Weight of the sand before drying, W2- Weight of the sand after drying.

Grain fitness test:

The grain size, distribution, grain fitness are determined with the help of the fitness testing of moulding sands. The apparatus consists of a number of standard sieves mounted one above the other, on a power driven shaker. The shaker vibrates the sieves and the sand placed on the top sieve gets screened and collects on different sieves depending upon the various sizes of grains present in the moulding sand. The top sieve is coarsest and the bottommost sieve is the finest of all the sieves. In between sieve are placed in order of fineness from top to bottom.

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Permeability test: The quantity of air that will pass through a standard specimen of the sand at a particular pressure condition is called the permeability of the sand. Following are the major parts of the permeability test equipment: 1. An inverted bell jar, which floats in a water. 2. Specimen tube, for the purpose of hold the equipment 3. A manometer (measure the air pressure).

Strength test: Measurements of strength of moulding sands can be carried out on the universal sand strength testing machine. The strength can be measured in compression, shear and tension. The sands that could be tested are green sand, dry sand or core sand. The compression and shear test involve the standard cylindrical specimen that was used for the permeability test.

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Mould hardness test: Hardness of the mould surface can be tested with the help of an “indentation hardness tester”. It consists of indicator, spring loaded spherical indenter.

The spherical indenter is penetrates into the mould surface at the time of testing. The depth of penetration w.r.t. the flat reference surface of the tester. Mould hardness number = ((P) / (D – (D2 -d 2 )) Where, P- Applied Force (N) D- Diameter of the indenter (mm) d- Diameter of the indentation (mm)

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6.MOULDING MACHINE

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7.TYPES OF CASTING EXPENDABLE MOLD CASTING: Expendable mold casting is a generic classification that includes sand, plastic, shell, plaster, and investment (lost-wax technique) moldings. This method of mold casting involves the use of temporary, non-reusable molds.

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8.TERMINOLOGY Metal casting processes uses the following terminology:-

DRAG: - The bottom half of the pattern, flask, mold, or core. COP: - The top half of the pattern, flask, mold, or core. RISER: - An extra void in the mold that fills with molten material to compensate for shrinkage during solidification. PARTING LINE: - This is the dividing line between the two molding flask that makes up the sand mould. In split pattern it is also the diving line between two halves of the pattern. SPRUE: - The pouring cup attaches to the sprue, which is the vertical part of the gating system. The other end of the sprue attaches to the runners. RUNNER: - The horizontal portion of the gating system that connects the sprues to the gates. MOLD CAVITY: - The combined open area of the molding material and core, where the metal is poured to produce the casting. CORE: - An insert in the mold that produces internal features in the casting, such as holes.

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9.PATTERN An approximate duplicate of the final casting used to form the mold cavity.

PATTERN MATERIAL: The usual pattern materials are wood, metal and plastics. The most commonly used pattern material is wood, the main reason being the easy availability and low weight. Also, it can be easily shaped and is relatively cheap. But the main disadvantage of wood is its absorption of moisture as result of which distortions and dimensional changes occur. A good construction may be able to reduce the warpage to some extent. Hence, proper seasoning and upkeep of wood is almost a pre-requisite for large-scale use of wood as a pattern material. The usual varieties wood commonly used for making patterns are pine, mahogany, teak, walnut and deodar. Besides the wood, the polywood boards of the veneer type as well as the particle boards are also used for making patterns.

A.SINGLE PIECE PATTERN: These are inexpensive and the simplest type of pattern. As the name indicates, They are made of a single piece. This type of pattern used in case where the job is very simple and does not create Any withdrawal problems. It is also used for applications in very smallscale production or in prototype development.

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B.SPLIT PATTERN OR TWO PIECE PATTERN: This is the most widely used type of pattern for intricate castings. When the contour of casting makes its withdrawal from the mould difficult, or when the depth of the casting is too high, then the pattern is split into two parts so that one part is in the drag and the other in the cope.

C.COPE AND DRAG PATTERN: These are similar to split patterns. In addition to splitting the pattern, the cope and drag halves of the pattern along with the gating and risering system are attached separately to the metal or wooden plate along with the alignment pins. They are called the cope and drag pattern. These types of patterns are used for castings which are heavy and inconvenient for handling as also for continuous production.

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D.MATCH PLATE PATTERN: These are extensions of the previous type. Here, the cope and drag pattern the risering are mounted on a single matching metal or wooden plate on either side. On one side of the match plate or cope flask is prepared and on the other, the drag flask. After moulding when the match plate is removed, a complete mould with gating is obtained by joining the cope and the drag together.

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10.CORES Cores are used to make holes, recesses etc. in castings So where coring is required, provision should be made to support the core inside the mould cavity. Core prints are used to serve this purpose. The core print is an added projection on the pattern and it forms a seat in the mould on which the sand core rests during pouring of the mould. The core print must be of adequate size and shape so that it can support the weight of the core during the casting operation. To produce cavities within the casting such as for liquid cooling in engine blocks and cylinder heads negative forms are used to produce cores. Usually sand-molded, cores are inserted into the casting box after removal of the pattern. Whenever possible, designs are made that avoid the use of cores, due to the additional set-up time and thus greater cost. With a completed mold at the appropriate moisture content, the box containing the sand mold is then positioned for filling with molten metal typically iron, steel, bronze, brass, aluminium, magnesium alloys, or various pot metal alloys, which often include lead, tin, and zinc. After filling with liquid metal the box is set aside until the metal is sufficiently cool to be strong. The sand is then removed revealing a rough casting that, in the case of iron or steel, may still be glowing red. When casting with metals like iron or lead, which are significantly heavier than the casting sand, the casting flask is often covered with a heavy plate to prevent a problem known as floating the mold. Floating the mold occurs when the pressure of the metal pushes the sand above the mold cavity out of shape, causing the casting to fail.

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Left: Corebox, with resulting (wire reinforced) cores directly below. Right:- Pattern (used with the core) and the resulting casting below (the wires are from the remains of the core) After casting, the cores are broken up by rods or shot and removed from the casting. The metal from the sprue and risers is cut from the rough casting. Various heat treatments may be applied to relieve stresses from the initial cooling and to add hardness—in the case of steel or iron, by quenching in water or oil. The casting may be further strengthened by surface

CORE PIECE

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11.FURNACE electric arc furnace (EAF) is a furnace that heats charged material by means of an electric arc. Industrial arc furnaces range in size from small units of approximately one ton capacity (used in foundries for producing cast iron products) up to about 400 ton units used for secondary steelmaking. TEMPERATURE RANGE:-Arc furnaces used in research laboratories and bydentists may have a capacity of only a few dozen grams. Industrial electric arc furnace temperatures can be up to 1,800 °C (3,272 °F), while laboratory units can exceed 3,000 °C (5,432 °F). Arc furnaces differ from induction furnaces in that the charge material is directly exposed to an electric arc, and the current in the furnace terminals passes through the charged material.

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12.POURING (GATING DESIGN) A good gating design should ensure proper distribution of molten metal without excessive temperature loss, turbulence, gas entrapping and slags. If the molten metal is poured very slowly, since time taken to fill the mould cavity will become longer, solidification will start even before the mould is completely filled. This can be restricted by using super heated metal, but in this case solubility will be a problem. If the molten metal is poured very faster, it can erode the mould cavity. So gating design is important and it depends on the metal and molten metal composition. For example, aluminium can get oxidized easily. Gating design is classified mainly into two (modified: three) types:  Vertical gating,  Bottom gating  Horizontal gating.

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13.SHAKEOUT MACHINE Shakeout Tables separate the poured mold into the flask, casting, and sand (green and no bake type). The casting deck configuration varies with the specific application. It can be made removable for change out. After the casting is reasonably cleaned of clinging sand, it is manually removed. The shakeout sand passes down through the casting deck openings and is collected for discharge through a bottom outlet. These Shakeout Tables are all powered by the Cinergy drive System. The available widths range from 2 ft. to 12 ft. in standard or heavy duty designs. The lengths are customized to our customer’s needs. Since the Cinergy drive System is energy efficient, power consumption is significantly reduced. It is adjustable in operating stroke and frequency by simple electrical control. This feature minimizes casting damage and noise. Maintenance checks are easily accomplished by the simple “look and listen” principle.

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14.MATERIAL SEPRATION In automatic foundry machines for the manufacture of castings in sand moulds it is known to perform the pouring while the casting moulds are carried on a conveyor on which the filled casting moulds are advanced to a knocking-out station provided with a grid. On this grid, the castings are separated from the mould material which drops down through the grid and is returned to the mould production apparatus. The intense heat from the metal poured damages the mould sand which therefore must be regenerated between the successive applications. As a rule, for the purpose of regeneration, a certain percentage of the mould sand is removed on its way from the knocking-out grid to the mould production apparatus and is substituted by unused material, which is mixed thoroughly with the remaining part of the mould sand, possibly with the addition of special components for improving the properties of the mould sand in various respects. Prior art foundry machines of this type cause a great deal of inconvenience, such as a high noise level and development of dust, heat and smell.

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15.DEFECTS IN CASTING A properly designed casting, a properly prepared mould and correctly malted metal should result in a defect free casting. However, if proper control is not exercised in the foundrysometimes it is too expensive - a variety of defects may result in a casting. These defects may be the result of: (a) improper pattern design, (b) improper mould and core construction, (c) improper melting practice, (d) improper pouring practice (e) Because of molding and core making materials. (f) Improper gating system (g) Improper metal composition (h) Inadequate melting temp and rate of pouring.

SURFACE DEFECTS: Due to design and quality of sand molds and general cause is poor ramming.

BLOW: Blow is relatively large cavity produced by gases Which displace molten metal form.

SCAR: Due to improper permeability or venting. A scare is a shallow blow. It generally occurs on flat surf; whereas a blow occurs on a Convex casting surface. A blister is a shallow blow like a scar with thin layer of metal covering it.

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SCAB: This defect occurs when a portion of the face of a mould lifts or breaks down and the recess thus made is filled by metal. When the metal is poured into the cavity, gas may be disengaged with such violence as to break up the sand which is then washed away and the resulting cavity filled with metal. The reasons can be: - to fine sand, low permeability of sand, high moisture content of sand and uneven moulds ramming.

INTERNAL DEFECTS: HOT TEAR: Hot tears are hot cracks which appear in the form of irregular crevices with a dark oxidized fracture surface. They arise when the solidifying met does not have sufficient strength to resist tensile forces produced during solidification.

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SHRINKAGE: A shrinkage cavity is a depression or an internal void in a casting that results from the volume contraction that occurs during solidification.

SWELL: A swell is a slight, smooth bulge usually found on vertical faces of castings, resulting from liquid metal pressure. It may be due to low strength of mould because of too high a water content or when the mould is not rammed sufficiently.

16.TESTING OF MATERIAL Mechanical Properties Mechanical testing gives an evaluation of the metal and the casting to determine whether the properties are in compliance with the specified mechanical requirements. Following are common mechanical tests used in metal casting facilities. Hardness testing: the most commonly used procedure for mechanical property testing, it provides a numerical value and is nondestructive. Hardness values generally relate to an alloy’s machinability and wear resistance. The brinell hardness test uses a 10-mm diameter carbide ball to indent a 3,000-kg load. The impressions are large enough to provide a dependable average hardness. Rockwell hardness tests make smaller indented impressions, which also can be satisfactory if the median of several values is used.

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Tensile and impact testing: conducted on test specimens of standardized dimensions, the two most common types are tensile and Charpy impact. Tensile testing provides ultimate tensile strength, yield strength, elongation and reduction of area data. Charpy impact testing determines the amount of energy absorbed during fracture and is used to gauge ductility and strength. Service load testing: usually conducted on the entire casting to evaluate its properties, it can be conducted in a number of ways. Castings that must carry a structural load can have a load applied in a fixture while the deflection and the load is measured. Pressurecontaining parts can be hydraulically tested to a proof load or destruction. Rotating parts can be spin tested. These types of tests check the soundness of the casting, as well as its properties.

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16.CONCLUSION In review this internship has been an excellent and rewarding experience. I have been able to meet and network with so many people that I am sure will be able to help me with opportunities in the future. One main thing that I have learned through this internship is time management skills as well as self-motivation. When I first started I did not think that I was going to be able to make myself sit in an office for six hours a day, six days a week. Once I realized what I had to do I organized my day and work so that I was not overlapping or wasting my hours. I learned that I needed to be organized and have questions ready for when it was the correct time to get feedback. From this internship and time management I had to learn how to motivate myself through being in the office for so many hours. I came up with various proposals and ideas that the company is still looking into using. I am going to continue to work for Steve Levine Entertainment although I am still keeping my options open for new opportunities. I enjoy this line of work, but I am not sure if there is enough room to grow through this company. I will continue to work hard in my position and hope to continue to learn about the industry and meet new people. This was an excellent experience and I hope that other interns got as much out of it as I did….!

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17.BIBLIOGRAPHY Self-training

WEBSITES o https://www.google.co.in o https://en.wikipedia.org

YOUTUBE

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