Six Weeks Vocational Training Undertaken At HMT LMT, Pinjore in Tractor Division on Study, Documentation And Manufacturing Of Various

Tractor Models And Its Parts Submitted In Partial Fulfillment Of Degree Of Bachelor Of Technology In Mechanical Engineering

UNDER THE GUIDANCE OF Mr. Sunil Sharma Designation- DGM Department Training Centre

SUBMITTED BY

ANKIT GUPTA
B-TECH MECHANICAL(3yr) 2511523

UNIVERSITY INSTITUTE OF ENGINEERING AND TECHNOLOGY

Vocational training report at HMT,LMT. PINJOREHMT

SUBMITTED TO
Mr. Sanjay kajal Head Of Department

SUBMITTED BY
ANKIT GUPTA B-TECH MECHANICAL(3yr)
2511523

ACKNOWLEDGEMENT
Acknowledgement is not only a ritual, but also an expression of indebtedness to all those who have helped in the completion process of the project. One of the most pleasant aspects in collecting the necessary and vital information and compiling it is the opportunity to thank all those who actively contributed to it. I would like to express my deep felt gratitude to ER. SANJAY KAJAL, Head Of Department ( Mechanical Engineering )for giving assistance to complete the project work, which is an important part of our curriculum. I am extremely grateful to SUNIL SHARMA (DGM), Training In charge , helped a lot in completing this work. Not only to fulfill the formality but also to express the feelings in my heart, we put on record our deepest grated and profound indebtedness to all of them who helped us by right guidance, upgrading our skills and troubleshooting while doing the assignments. At last but not the least, I would like to pay our sincere regards to the faculty members for their invaluable support & blessings, which were a vital necessity for the completion of our project work.

ANKIT GUPTA 2511523

CONTENT

COMPANY PROFILE HEAT TREATMENT ENGINE SHOP TOOL ROOM FOUNDARY TRACTOR ASSEMBLY ENGINE ASSEMBLY AND TESTING HEAVY MACHINE SHOP NEW ENGINE SHOP LIGHT MACHINE SHOP

LIST OF IMAGES
FIG. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NAME CNC MACHINE COMPANY OUTSIDE VIEW HEAT TREATMENT ANOTHER VIEW OF HEAT TREATMENT SURFACE HARDENING TOOLS LIQUID ALUMINIUM MOLTEN IRON HMT TRACTOR GEAR BOX DIFFERENTIAL ENGINE ANOTHER VIEW OF ENGINE CRANKCASE MT HOUSING CYLINDER HEAD PAGE NO. 7 7 8 8 11 13 14 15 16 18 18 21 22 23 23 24

COMPANY PROFILE
HMT was the fulcrum on which the industrial development of India was envisaged. It was set up in 1953 to meet the challenge and take up the pioneering role in the development of machine tool HMT successfully diversified into diversified areas of engineering. Leading this diversification drive was the HMT Tractor Business Group. Since its inception in 1971, HMT Tractor Business Group has increasingly contributed its might in building HMT into an organization to reckon with. Presently Tractor Business Group is part of HMT Ltd., the holding company of HMT Group. The passing years, saw the needs of the Indian farmer change. Farm mechanization was growing HMT stepped in by introducing tractors that met the specific needs of the agricultural sector. HMT manufactures a wide range of tractor from 25 HP to 75 HP. Keeping in tune with HMT's philosophy of introducing innovative products and continuously upgrading its tractors with better technology, these models incorporate contemporary technology viz. fuel efficient engine meeting emission norms, floor gears, direct axle, latest styling giving value for money to its customers. Strong Manufacturing Base: HMT's Tractor Project commenced its operations from Pinjore in June 1971.This unit is the main unit today fully integrated with foundry, manufacturing, assembly and testing facilities for 20000 tractors and engines. Beside, assembly unit at Hyderabad (Andhra Pradesh, India). The Tractor unit is certified with ISO 9001 Quality Standards VISION: To Be an Engineering Company of International Repute, Providing Best of Products & Services With Contemporary Technologies To suit customer needs MISSION: To achieve sustained growth and profitability. To strive for competitiveness and excellence in performance. To ensure stakeholders' satisfaction in its business. To develop and upgrade skills and capabilities of employees through Human Resource Development.
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MACHINES

Fig. 1 CNC MACHINE The HMT Pinjore Complex is spread over 850 acres. Apart from factory, Rod, Camshaft, Bearing Caps, Gears, Shafts, Crown wheel and Pinion. INFRASTRUCTURE

Fig.2 COMPANY OUTSIDE VIEW

The HMT Pinjore Complex is spread over 850 acres. Apart from factory, it houses township,schools, banks and clubs for all round community welfare.

HEAT TREATMENT
Heat treatment is a group of industrial and metal working used to alter the physical and chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, tempering,quenching. It is noteworthy that while the
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term heat treatment applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding.

Fig.3 HEAT TREATMENT EFFECT OF TIME AND TEMPERATURE Proper heat treating requires precise control over temperature, time held at a certain temperature and cooling rate. With the exception of stress-relieving, tempering, and aging, most heat treatments begin by heating an alloy beyond the upper transformation temperature. The alloy will usually be held at this temperature long enough for the heat to completely penetrate the alloy, thereby bringing it into a complete solid solution. Since a smaller grain size usually enhances mechanical properties, such as toughness and strength.

Fig.4 ANOTHER VIEW OF HEAT TREATMENT

HEAT TREATMENT PROCESSES Hardening Annealing Normalizing Tempering

Surface Hardening

HARDENING Hardening is performed to impart strength and hardness to alloys. By heating up to a certain temperature, depending on the material and cooling it rapidly. Steel is heated and held there until its carbon is dissolved, and then cooled rapidly, the carbon does not get sufficient time to escape and get dissipated in the lattice structure. This helps in locking the dislocation movements when stresses are applied. Quenching is performed to cool hot metal rapidly by immersing it in brine (salt water), Water, oil, molten salt, air or gas. Quenching sets up residual stresses in the work piece and sometimes results in cracks. ANNEALING Annealing is performed to reduce hardness, remove residual stresses, improve toughness, restore ductility, and to alter various mechanical, electrical or magnetic Cooling rate is very slow around 100 deg C per hour.
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 Process is carried out in a controlled atmosphere of inert gas to avoid oxidation. Used to achieve ductility in work hardened steels. NORMALIZING The process is similar to annealing and is carried out to avoid excessive softness in the material. The material is heated above austenitic phase (1100 C) and then cooled in air. This gives relatively faster cooing relatively fastercooling and hence enhanced hardness and less ductility. Normalizing is less expensive than annealing. In normalization variation in properties of different sections of a part is achieved. The selection of heat treatment operations is strongly influenced by the carbon content in the steel. TEMPERING Martensite is very hard and brittle. Tempering is applied to hardened steel to reduce brittleness, increase ductility, and toughness and Relieve stresses in martensite structure. In this process, the steel is heated to lower critical temperature (350--400 C) keeping it there for about one hour and then cooled Slowly at prescribed rate. This process increases ductility and toughness but also reduces Hardness, strength and wear resistance marginally. Increase in tempering temperature lowers the hardness.

SURFACE HARDENING Heat treatment methods in general change the properties of entire material. Hardening improves wear resistance of material but lowers impact resistance and fatigue life. Therefore sometimes there is requirement of surface hardening Two methods are used, first is heating and cooling to get required Phase, and second is thermochemical treatment.
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Fig.5 SURFACE HARDENING

ENGINE SHOP
PARTS OF ENGINE FRONT COVER :Front cover is used to cover the front part of the crankcase.

REAR COVER :Rear cover is used to cover the rear cover of the crankcase. CAM SHAFT:Cam shaft helps in closing and opening of the valves. Valve tapered is mounted on the cams of cam shaft and push rod is mounted on valve tapered which is connected to the rocker arm. One end of rocker arm is connected to the valves placed on the cylinder head. Once the cam shaft revolves it pushes the valve tapered and push rod which hits the rocker arm and which results in opening and closing of valves. CONNECTING ROD:-

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One end of it is connected to piston and other end is connected to crank shaft. It helps the piston to move up and down. It helps to make the connection between crankcase and piston. INTER GEAR PIN FRONT BEARING CAP:It makes the crank shaft to be rotated smoothly. Roller bearing is inserted in it and crankshaft is inserted in this bearing which makes the smooth rotation of crankshaft. This bearing is attached to the front part of crankshaft. REAR BEARING CAP:It makes the crank shaft to be rotated smoothly. Roller bearing is inserted in it and crankshaft is inserted in this bearing which makes the smooth rotation of crankshaft. This bearing is attached to the rear part of crankshaft.

CENTRE BEARING CAP:It makes the crank shaft to be rotated smoothly. Roller bearing is inserted in it and crankshaft is inserted in this bearing which makes the smooth rotation of crankshaft. This bearing is attached to the central part of crankshaft. IPD BUSH Used to protect the work piece from damage VALVE TAPERED:It is placed on the cams of cam shaft to hit the rocker arm with the help of push rod. CRANKCASE:It is that of the engine in which the entire part of the engines are mounted. It designed in that way such that the entire part of the engines are easily clamped. CYLINDER HEAD:It is that part of the engine on which valves are mounted. Fuel injector are also placed on it. It also helps in water circulation. OIL SPAN Lubricating oil is placed in it. It helps in the lubrication of the various engine parts.

STEPS INVOLVED IN THE MAKING OF CAM SHAFT Material cutting

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 Centering Copy turning Flange cut Plan turning Straightening Bench drill Cam turning Cam grinding and fitting Gas carburizing Straightening Case hardening Cylinder grinding Cam grinding Key way Inspecting

TOOL ROOM
In tool room various small parts of engine are made. Operations like drilling, milling, grinding , tapping , broaching , chamfering , knurling , centering , etc are done with great ease. For these types of operations various types of broach tools are used. Gear manufacturing also takes place in tool room. Various gear hobbing machines are placed in tool room to produce gears. These gear hobbing machines uses a different types of cutters to produce various types of gears like bevel gears, sun gears, planet gears, speed gears, spur gears, parallel gears, helical gears, etc .

Fig.6 TOOLS
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FORMULAES USED IN MANUFACTURING OF VARIOUS TYPES OF GEARS

1) Constant x G Z

Constant - 12 or 24 G Number of initials on cutters (it is 1 , 2 ,3) Z Number of teeths

2) M X Z + 2 = outside diameter M Module

FOUNDRY
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such s bronze, brass, magnesium , steel , zinc are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.

Fig.7 LIQUID ALUMINIUM

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PROCESSES
MELTING Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace.

FURNACE Several specialized furnaces are used to melt the metal. Modern furnace types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces

Fig.8 MOLTEN IRON

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MOLD MAKING In the casting process a pattern is made in the shape of the desired part. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. The pattern is made out of wax, wood, plastic or metal

POURING In a foundry, molten metal is poured into molds SHAKEOUT After solidification of metal, it is put on the vibrate to get rid of the burnt sand. Now then we left out with the metal casting. HEAT TREATMENT Heat treating is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material.

TRACTOR ASSEMBLY
In tractor assembly we have learnt how to assemble the different parts of tractor to make it working. All the tractors parts should me assemble to each other precisely.

Fig. HMT TRACTOR

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TRACTORS PARTS Gear box Differential MT housing Mechanical brakes Hydraulic brakes Steering Radiator Thermostat Engine Lift GEAR BOX Gear box consist of various types of gears to increase and decrease the speed of the tractor. Gear box is made in heavy machines shops where it has to move through various processes like marking, drilling, reaming, boring etc. GEAR BOX CONSIST OF FOLLOWING PARTS Speed gears Lay shaft Spline shaft Reduction shaft Power transmission shaft Clutch shaft Hollow shaft Bevel pinion shaft

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Fig.9 GEAR BOX MT HOUSING In MT housing differential is safely placed.MT housing consists of differential, crown wheel , differential shaft , etc. it is connected the gear box. DIFFERENTIAL Differential is a device which is used to provide a turn to the vehicle. It consists of 2 sun wheel , 4 planet wheels , 2 planet wheels , Crown wheels. When a vehicle is supposed to take a turn one side of the vehicle gets pressurized and its rpm gets cut off and with the help of differential equally reduced rpm of the one wheel gets transferred to the other rear wheel and then vehicle is supposed to get turn.

Fig. 10 - DIFFERENTIAL

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MECHANICAL BRAKES It consists of 3 discs which are placed one over another. Several rollers are placed in between the 3 discs. These 3 discs are attached to the lever. When the lever is pulled the 3 discs turn over the rollers and touches the outer cover of the mechanical brake. When disc touches the outer cover of the mechanical brake , the disc stops revolving and differential shafts also gets stop. As differential shaft gets stops it makes the wheel also stops moving . HYDRAULIC BRAKES It is most powerful brakes and considered as best in comparison to the mechanical brakes. When it applies it stops the vehicle immediately rather covering some distance as in mechanical brakes. It consists of following parts like hydraulic fluid , equalizer , 2 muscle cylinder , 2 brake shoes . when brakes are applied fluid gets transferred the cylinder placed in the hydraulic brakes and pushes the pistons inside the cylinder with great pressure. As the piston gets pulled out it pushes the brake shoes and brake shoes gets touched with the brake drum and brake drum stops revolving . As differential shaft is attached to the brake drum and if brake drum gets stopped the differential shaft also stops rotating and makes the wheel to stop rotating. RADIATOR Radiator is placed on the front part of the tractor . it is used to make the hot water cooler. It helps in making the hot water cool and then delivered again to the engine. THERMOSTAT Thermostat is used to sense the water temperature coming out of the engine. If it is less than 80 degree it returns the water to the engine.

ENGINE ASSEMBLY AND TESTING

In engine assembly we have learnt how to assemble the various parts of engine in the crankcase. Steps to assemble the parts of engine in crankcase

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 Firstly crankshaft is placed in the crankcase. Then bearing caps are mounted over the crankshaft. Then cam shaft is fitted beside the crankshaft. Then gears are attached to the ends of crankshaft , cam shaft , and IPD shaft. Then connecting rod is attached to the crankshaft. Then connecting rod is attached to the piston with the help of gudgeon pin. Oil pan is placed below the engine. Mobile oil filter , compressor, are also attached to their required position according to the design. Valve tapered , push rod and rocker arm is mounted over cam shaft. Then cylinder head is placed. Then valves are attached to the rocker arm over cylinder head. Then fuel injector are mounted to the left side of the engine. Then fuel injection pipes are attached to the cylinder head. Then water pipe , air pipe , exhaust pipe are attached to it. Then turbocharger is attached to the exhaust pipe . Then exhaust air cooler is attached to it. Flywheel assembly is attached to the front part of the engine . Then self starter is attached which makes the flywheel to rotate.

WORKING

When we switch on the self starter, the flywheel starts rotating and crank also starts rotating. The corresponding cam shaft and IPD shaft gets rotation motion from the crank shaft. As crank shaft rotates the piston moves up and down. The cam shaft makes the valves open and close. As the valve open the fuel gets injected inside the piston. The piston compresses the air and when fuel gets injected into it, bombardment takes place which push the piston backwards and make the crank shaft to move with more power and this power and motion is transmitted to the wheels. The piston compresses the air and when fuel gets injected into it, bombardment takes place which push the piston backwards and make the crank shaft to move with more power and this power and motion is transmitted to the wheels.

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Fig.11 ENGINE

FOUR STROKE DIESEL ENGINE

Intake stroke -- The intake valve opens up, letting in air and moving the piston down. Compression stroke -- The piston moves back up and compresses the air. Combustion stroke -- As the piston reaches the top, fuel is injected at just the right moment and ignited, forcing the piston back down.

Exhaust stroke -- The piston moves back to the top, pushing out the exhaust created from the combustion out of the exhaust valve TWO-STROKE DIESEL CYCLE

When the piston is at the top of its travel, the cylinder contains a charge of highly compressed air. Diesel fuel is sprayed into the cylinder by the injector and immediately ignites because of the heat and pressure inside the cylinder. This is the same process described in how diesel engine works. The pressure created by the combustion of the fuel drives the piston downward. This is the power stroke. As the piston nears the bottom of its stroke, all of the exhaust valves open. Exhaust gases rush out of the cylinder, relieving the pressure.

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 As the piston bottoms out, it uncovers the air intake ports. Pressurized air fills the cylinder, forcing out the remainder of the exhaust gases. The exhaust valves close and the piston starts traveling back upward, re-covering the intake ports and compressing the fresh charge of air. This is the compression stroke. As the piston nears the top of the cylinder, the cycle repeats with step 1

Fig.12 - ENGINE

HEAVY MACHINE SHOP

In heavy machine shop we have learnt how to make drilling ,boring , grinding , tapping , chamfering , internal finishing , etc in gear box and crankcase. Firstly marking is done for drilling with white paint with the help of machine. Then punching is made on the marked place for drilling. Then the gear box and crankcase is forward to the next machine where drilling has to be done on the marked position. Then boring has to be done according to the required diameter. Then finishing is done with the help of grinding wheel. The gear box and crank case are prepared on the different sections in the heavy machine shops.

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Fig.13 CRANKCASE

NEW ENGINE SHOP

In this we have learnt the making of cylinder head and crankcase. All the drills made on cylinder head are made in this shop. Holes made for valves, fuel injector, rocker arm , push rod are made in this shop. Special purpose machines are used to perform all these operations. CNC machines are also used to perform the same type of operations.

FIG. 14 MT HOUSING

LIGHT MACHINE SHOP

There are two sections in this shop Auto parts Gear manufacturing AUTO PARTS Auto parts includes differential, crown wheels etc. Differential cage (right or left cage) are made in this section accurately and precisely.
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Fig.15 CYLINDER HEAD GEAR MANUFACTURING Gear manufacturing also takes place in this shop. Various gear hobbing machines are placed in tool room to produce gears. These gear hobbing machines uses a different types of cutters to produce various types of gears like bevel gears , sun gears , planet gears , speed gears , spur gears , parallel gears , helical gears , etc .

FORMULAES USED IN MANUFACTURING OF VARIOUS TYPES OF GEARS Constant x G Z

Constant - 12 or 24 G number of initials on cutters (it is 1 , 2 ,3) Z number of teeths

M X Z + 2 = outside diameter M module

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