SIXTH MONTH INDUSTRIAL TRAINING PROJECT REPORT

ESCORTS INDIA PVT. LTD. Crank Shaft & Hydrolic Plant GROUP, FARIDABAD

METHODS INVOLVED IN THE PROCESS OF PRODUCTION OF REAR AXLE

Project Head

Mr. Sukhpal Sir

Prepared By :

Sushil Kumar
Roll No. - 100390593941 B-tech Electrical

GURU RAM DAS ENGINEERING COLLEGE, LEHRA BEGHA

PREFACE

Industrial exposure is the most crucial part of the technical studies in which a student is able to synchronize his technical knowledge with practical knowledge gained in any of the organization in which he gets his training from. I was allotted a project titled, Methods involved in the process of Production of REAR AXLE, in ESCORTS INDIA PVT LTD, FARMTRAC DIVISION. I hope that the word of my project communicates the actual experience gained with subtlety and precision, which is unapproachable, by any other means. From the medium of this project report, I would like to thank each and every honorable employee of ESCORTS INDIA PVT LTD FARMTRAC DIVISION, who has helped me to gain all the knowledge in the respective production shop, where production process was involved.

INDEX

Company Profile The Founding Philosophy Background Overview Manufacturing Overview Material Management Methods Involed Design Final Inspection

COMPANY PROFILE

ABOUT THE COMPANY

The Escorts Group is among India's leading engineering conglomerates operating in the high growth sectors of agri-machinery, construction & material handling equipment, railway equipment and auto components.

Having pioneered farm mechanization in the country, Escorts has played a pivotal role in the agricultural growth of India for over five decades. One of the leading tractor manufacturers of the country, Escorts offers a comprehensive range of tractors, more than 45 variants starting from 25 to 80 HP. Escort, Farmtrac and Powertrac are the widely accepted and preferred brands of tractors from the house of Escorts. A leading material handling and construction equipment manufacturer, we manufacture and market a diverse range of equipment like cranes, loaders, vibratory rollers and forklifts. Escorts today is the world's largest Pick 'n' Carry Hydraulic Mobile Crane manufacturer.

Escorts has been a major player in the railway equipment business in India for nearly five decades. Our product offering includes brakes, couplers, shock absorbers, rail fastening systems,composite brake blocks and vulcanized rubber parts. In the auto components segment, Escorts is a leading manufacturer of auto suspension products including shock absorbers and telescopic front forks. Over the years, with continuous development and improvement in manufacturing technology and design, new reliable products have been introduced.

Throughout the evolution of Escorts, technology has always been its greatest ally for growth. In the over six decades of our inception, Escorts has been much more than just being one of India's largest engineering companies. It has been a harbinger of new technology, a prime mover on the industrial front, at every stage introducing products and technologies that helped take the country forward in key growth areas. Over a million tractors and over 16,000 construction and material handling equipment that have rolled out from the facilities of Escorts, complemented by a highly satisfied customer base, are testimony to the manufacturing excellence of Escorts. Following the globally accepted best manufacturing practices with relentless focus on research and development, Escorts is today in the league of premier corporate entities in India.

Technological and business collaboration with world leaders over the years, Globally competitive indigenous engineering capabilities, over 1600 sales and service outlets and footprints in over 40 countries have been instrumental in making Escorts the Indian multinational. At a time when the world is looking at India as an outsourcing destination, Escorts is rightly placed to be the dependable outsourcing partner of world's leading engineering corporations looking at outsourcing manufacture of engines, transmissions, gears, hydraulics, implements and attachments to tractors, and shock absorbers for heavy trailers.

In today's Global Market Place, Escorts is fast on the path of an internal transformation, which will help it to be a key driver of manufacturing excellence in the global arena. For this we are going beyond just adhering to prevailing norms, we are setting our own standards and relentlessly pursuing them to achieve our desired benchmarks of excellence.

THE FOUNDING PHILOSOPHY

Over six decades back two young men set out on a journey together armed with little beyond intelligence, business acumen and determination and dreams aplenty. They believed that India could only achieve total freedom with a breakthrough in the field of agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had kindled the hope that one day they would make a mark of their own. They were in fact writing the first chapter of what has come to be widely recognized as one of the greatest success stories in Indian industry. Escorts came into being with a vision. A vision that eschewed easy paths to profitability, and sought instead for ways to make a contribution. A vision that led two young brothers, Yudi and Hari Nanda, to branch out of their family's prospering transport business and institute ventures that were to become the foundations of Escorts Limited. On 17th October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting marketing house driven by the same business philosophy, which had given their family enterprise an unrivalled reputation: customer concern. Not long afterwards, this driving ambition to go beyond the expected led Hari Nanda to the first of his many successful business insights - the discovery of the great business potential that lay in India's villages. This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda as Director. Though separate business entities then, both companies had two great strengths in common: the dynamic Nanda brothers and the unifying force of the name they gave their companies; Escorts, literally 'escorting' their products and services to the customer while most other businessmen were just selling. Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit remained embedded in the foundations of the company. Mr. H P Nanda then took on the mantle to realize the dreams which he had always seen with his brother.

Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged in 1953 to create a single entity -Escorts Agents Pvt Ltd. Having initially started with a franchise for Westinghouse domestic appliances, by this time the Company had already expanded its marketing and service operations, representing internationally known German and American organizations such as MAN, AEG, Haniel&Leug, Knorr Bremse, MIAG and BMA for sophisticated electrical and mechanical engineering equipment and Minneapolis Moline and Wisconsin for agricultural tractors, implements and engines. Escorts made a major thrust into the agricultural arena by taking on the marketing and service franchise for Massey Ferguson tractors in Northern India, which soon comprised 75% of MF's all-India sales - a signal tribute to Escorts' inherent strengths. Its first industrial venture came up in 1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings and cylinder liners - followed by production of pistons in collaboration with MAHLE, also of Germany, in 1960. The company's incorporation in its present name, Escorts Limited, was effected on 18th January, 1960. Escorts' next major industrial activity was the assembly of tractors in 1961 in technical cooperation with URSUS of Poland. Subsequently this led to the manufacture of the country's first indigenous tractors under Escorts' own brand name, which were to play a pivotal role in the Green Revolution. This went on to lay the foundations that even today are the Company's core strengths -relevant, world-standard technology through strategic international alliances; a broadbased marketing and service network yet unrivalled.

Beyond the growth of the organization, these principles have ensured that Mr. H. P. Nanda's contribution to the cause of industry and the consumer will endure. He pioneered the revolutionary concept of 'interdependence' between ancillary and large industries, institutionalizing vendor development and in the process building Faridabad and the entire belt of townships in the region. He introduced the discipline of service going before marketing, reassuring the customer that Escorts would stay with them, that they were here for the long run. He built lasting alliances with an array of the world's most respected names in tractors, industrial equipment, two-wheelers, construction equipment and

telecommunications. Going further, he created institutions devoted to value engineering and training, not only as investments in the company's future but also as catalysts for the enhancement of Indian industry as a whole the Escorts R&D Centre and the unique Escorts Institute of Farm Mechanization. His concern extended to the society in which he worked, and he manifested it by establishing the Escorts Medical Centre at Faridabad, Escorts Heart Institute and Research Centre at New Delhi, as well as numerous village development programmes. And above all, he imbued the corporation with his own pioneering.

Escorts is testimony to the valor, vision and values of its Founder Mr. H P Nanda. He remains the inspiration for our courage, spirit of adventure and ability to Think Big. These qualities are his enduring legacy and have inspired and encouraged us down the decades and will continue doing so in all our endeavors.

Background

In 1960, our parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture into tractors. In 1965, we rolled out our first batch of tractors under the brand name of Escort. In 1969 a separate company, Escorts Tractors Ltd., was established with equity participation of Ford Motor Co., Basildon, UK for the manufacture of Ford agricultural tractors in India. In the year 1996 Escorts Tractors Ltd. formally merged with the parent company, Escorts Ltd. Since inception, we have manufactured over 1 million tractors.

Overview Manufacturing
Escorts - AMG has Tractor manufacturing capacity of 98,940 trs / annum which is the highest in Asia at one location. Its manufacturing operations are divided in three plants as Component Plant Tractor Assembly Plant Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings such as Engine blocks, Gear Box housings, Differential housings are being machined along with Gears & Shafts. Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centers, CNC Turning Centers and variety of other precision machines, including Gear Hobbing and Shaving machines, etc. It is important to note that all critical components are machined in house. Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line. Farmtrac Line is a composite line that has machining as well as assembly activities of Engine, Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine, Transnmission& Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that includes AVL make Eddy Current Dynamometers in Engine Test House. Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are being machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State of the Art Honing and other precision machines.

Overview Materials Management

Presently procuring materials for 72,000 tractors per annum. Present procurement value over US$ 30 million. Production will rise to 100,000 tractors per annum in 2 years. Procurement value will rise to almost US$ 45 million in that period. Presently 387 suppliers of which over 95% are India domestic. Advantages of low costs of materials in India. Items procured are:
Castings Forgings Machined Parts Proprietaries Sheet Metal Hardware

METHODS INVOLVED IN THE PROCESS OF PRODUCTION OF REAR AXLE

DESIGN OF THE REAR AXLE SHAFT

REAR AXLE PRODUCTION UNIT

S. No 1 OPERATION DESCRIPTION FINISH TURNING OF BIG END FLANGE MACHINE EQUIPMENT NCL-15; NCL-16 KWS MAKE CNC LATHE OPERATION 1. DRUM DIA 2. BIG END FLANGE DIA 3. LENGTH OF DRUM DIA 4. FLANGE WIDTH 5. LENGTH OF SEAL DIA 6. LENGTH OF BEARING DIA 7. THREAD SIZE 8. THREAD LENGTH 9. LENGTH OF SPLINES 10. LENGTH OF SEAL DIA 11. STEM DIA 12. FILLET RADIUS OF STEM TAPER DIA 13. SURFACE FINISHING OF STEM TAPER DIA 1. BOLT HOLE DIA 2. BOLT HOLE COORDINATES 3. MANUFACTURING HOLE DIA 4. MANUFACTURING HOLE CO-ORDINATES 1. OIL GROOVE DEPTH 2. OIL GROOVE PROFILE 1. CHAMFER DIA 2. CHAMFER ANGLE 1. NO OF SPLINES DIA OVER MEASURING PINS. 2. PCD RUNOUT 3. LENGTH OF SPLINES 1. EFFECTIVE CASE DEPTH ON STEM 2. EFFECTIVE CASE DEPTH TOWARDS FLANGE DIA 3. EFFECTIVE CASE DEPTH AT REST DIA OF SPLINES 4. EFFECTIVE CASE DEPTH AT ROOT OF M-642 THREADS CYCLE TIME(MINUTES) 8.99(57 JPS)

2.

3.

4.

5.

DRILL AND FINISH HOLE MILL 8 NOS BOLT HOLES THROUGH AND DRILL 2 NOS MANUFACTURING HOLES FORM OIL GROOVE ON STEM END FACE CHAMFERING OF BACK FACE OF 8 NOS BOLT HOLES MILLING OF 38 INVOLUTE SPLINES ON STEM END WASHING OF COMPONENT

HMD-19 BATLIBOL MAKE MULTIDRILLING MACHINE

4.25(124 JPS)

ETL-01

3.43(140 JPS)

VLM-03

3.43(140 JPS)

SMM-02 HURTH MAKE SPLINE MILLING MACHINE WSM-01 THERMAS MAKE WASHING MACHINE

3.55(104 JPS)

6.

5(80 JPS)

7.

INDUCTION HARDENING OF SHAFT STEM

IHM-03 IHM-04

5. HEAT RUNOUT ON SPLINED END 1. QUENCHING MEDIA 2. TEMP OF QUENCHING MEDIA 3. PRESSURE OF QUENCHING MEDIA 4. RADIAL GAP B/W INDUCTOR & COMPONENT 5. FACE GAP B/W INDUCTOR AND COMPONENT 6. QUECH LAG TIME 7. PRE HEATING TIME 8. POWER REQUIRED 9. SPINDLE SPEED 10. INDUCTOR TRANSVERSE RATE

8.

CHECK FILE HARDNESS AT NECK & STEM 9. NORMALISE THE SHAFT IF REQUIRED FOR REWORK 10. FLANGE HARDENED STEM AND FACE 11. TEMPER THE INDUCTION HARDENED SHAFT 12.

13.

14.

15.

IHM-04 INDUCTION HARDENING MACHINE FLANGE HARDENING EQUIPMENT TFF-04 SURFACE HARDNESS TFF-05 TEMPERING FURNACE STRAIGHTENING HDP-05 RUNOUT ON 47 INVOLUTE OF SHAFT STEM BEMCO MAKE SPLINE DIA HYDRAULIC PRESS GRINDING OF AGR-07 1. SEAL DIA SEAL DIA & FINISH ANGULAR HEAD 2. BEARING DIA GRINDING OF GRINDER 3. SURFACE FINISH ON BEARING DIA & BEARING DIA BEARING SEATING 4. DIST OF BEARING FACE SEATINGFACE FROM FLANGE FRONT FINISH GRINDING ANGULAR HEAD LENGTH OF SEAL DIA OF SEAL DIA GRINDER SURFACE FINISH OF SEAL DIA AGR-05 FINISH GRIND MTC-01 1. SURFACE FINISH OF STEM AND FACE FACE GRINDING STEM END FACE EQUIPMENTS 2. LENGTH OF STEM END FACE wrt BEARING STEATING

TEMP OF TEMPERING TEMPERING PERIOD

3.45(139JPS)

2.91(165 JPS)

4.21(132 JPS)

16. SUPER FINISH OF SEAL DIA

16. CHECK CRACK ON REAR AXLE SHAFT 17. FINAL INSPECTION OF SHAFT REAR AXLE

SFM-02 SUFFINA MAKE SUPER FINISHING MACHINE MAGNA FLUX CRACK DETECTOR STAGE

FACE 1. SEAL DIA SURFACE FINISH OF SEAL DIA

2(132 JPS)

1. FREE FROM CRACKS 2. AS PER PART PRINT SPECIFICATION 2(132 JPS)

OPERATIONS PERFORMED
FINISH TURN SHAFT REAR AXLE AND CUT THREADS

MACHINE TYPE-

NCL-15;NCL-16
FEED 0.016/0.20 0.006/0.12 0.0787/RN 0.012/RN SPEED 750ft/mtr 750ft/mtr 650ft/mtr 700ft/mtr

CUTTING PARAMETERS:TOOL NO 06 07 0101 04

GAUGE USED 1. 2. 3. 4. 5. 6. 7. 8. G-30327 G-85004/2 G-30405 G-85004/1 G-30329 G-30327 G-30345 G-30343

TESTING SHAFT RUNOUT CHECKING AFTER CNC

OPERATERS PROCEDURE(BENCH CENTRE) 1. 2. 3. 4. 5. MOUNT THE COMPONENT ON CENTRE SHAFT SHOULD BE ALLIGN WITH CENTRE CHECK THE SHAFT FOR ROTATION ON THE CENTRES. MOUNT THE DIAL GAUGE ON THE TABLE & CHECK THE RUNOUT. CHECK THE RUNOUT & IF CHANGE IN DIMENSION, THEN CHECK THE FEED ON THE MACHINE.

TO DRILL AND REAM 8 BOLT HOLES ON FLANGE

DRILL TWO MANUFACTURING HOLES. OPERATION POSITION OF 8 HOLES AFTER DRILLING POSITION OF 8 HOLES AFTER MILLING DIA 740/.760 DIA .6675/.6595(HOLE MILL) GAUGES 4235 AAEG 27 4235 AAEG 4 G-40088 g-40087 CHECKING FREQUENCY 1 SHIFT 1 SHIFT 1/50 1/10

DRILLS USED- 4235AA-ET-85A

HOLE MILLS4235AA ET 86A 4235AA EG 27 7235 AA EG 4 LIMIT GAUGES- G-40088 G-40087

OIL GROOVE ON STEM END FACE

CUTTER USED - FM CUTTER 4235 AET 5 CUTTING SPEED- 800 RPM FEED- BY HAND

GAUGE TO CHECK 4235 AEG 6

CHAMFER ON 8 HOLES

CHAMFER SIZE - .070+ 0.10X45 CHECKING FREQUENCY- 1/160 TOOL USED-TS COUNTERSUNK CUTTER DIA 3/4X90

FINISH MILL 38 & 47 INVOLUTE SPLINES

TOOL & M/C SETTINGSCUTTER- 4235A ET 83(FOR 47 SPLINE) REEMER - 4235A-ET 9(FOR 38 SPLINES) FACE CENTRE - 4235AA EF 44/1 TAIL STOCK CENTRE - MA-321/25 GAUGES USED4235 EG 71 4235 AEG 29 4235 AEG 28 4235 AEG 72 SPEED - 180 RPM FEED - 400M/MIN

SHAFT INDUCTION HARDENING

QUENCH PRESSURE = 5-7.5 Kg/cu.cm QUENCH TEMPERATURE = 25C-45C GAP = 0.085/.110

TEMPER INDUCTION HARDENING OF SHAFT

FURNACE TEMPERATURE- 230C-240C TIME PERIOD- 1.5-2.5 HRS CHARACTERISTICSCHANGE OF BASE COLOUR TO GOLDEN COLOUR.

GRIND SEAL DIAMETER

GRINDING WHEEL - 4235 AET 87 CENTRE - MT-5(2 NOS) DRESSING DIAMOND - MA 902/37

FINISH GRIND SEAL DIAMETER

TAPER CUT GRINDING WHEEL :- 100/68X40X31.75 SUPER FINISH SEAL DIA :- 2.105/2 STONE USED :- 60mmX60mmX18mm OSCILATOR DRIVE PRESSURE :- 1.5 2.5 BAR.

STAGE INSPECTION
CHECK LIST:1. 8 NOS BOLT HOLE DIA OF 0.6675/0.6595 2. SEAL DIA OF 2.100/2.105 3. SEAL DIA OF 2.6265/2.6275 4. LENGTH OF 29.096/29.042 5. 38 SPLINE FOR ALLIGNMENT 6. 47 SPLINE FOR ALLIGNMENT 7. IF ABOVE COMPONENT IS TIGHT THEN IT IS SENT FOR REWORK.

CRACK CHECKING(MAGNA FLUX)

CURRENT RATING :- 2200-2800 AMPS IF BLUE LIGHT SHOWS THEN PIECE IS REJECTED OTHERWISE PASSED WITH OK SIGN.

Bibliography www.google.com www.wikipedia.com www.escortagri.com Text Books Company Production Documents