PROJECT REPORT ON

STUDY AND UPDATION OF PROCESS OF CLYNDER

(BLOCK E 3-312)

UNDERTAKEN AT

SUBMITTED TO:-

SUBMITTED BY:-

(DEPARTMENT OF MECHANICAL ENGG)

CHETAN GOSAIN
ROLL NO: 10512
MECHANICAL ENGG.
4TH YEAR/ 7TH SEMESTER

ACKNOWLEDGEMENT
I am very grateful to ESCORTS
AGRI MACHINERY (COMPONENTS
PLANT)

AT

PLANT

NO

Management which gives me the

opportunity

to

work

in

their

organization. Through this training I

was able to get a feel of working in
an

industry

and

could

put

to

practice the knowledge I had gained

so far in my college. I am greatly
indebted to my Project supervisor

and the senior engineer Mr. SUNIL

SANDHU , who in spite of his busy
schedule guided me in my project
and was always also available for
discussion. He took active interest
in my training period and inspired
me to use this great opportunity to
learn about the various aspects of
seat slider, recliner and not just
limit myself to assigned the project.
Chetan gosain

COMPANY PROFILE
OVERVIEW
ESCORTS LIMITED,THE FLAGSHIP COMPANY OF THE ESCORTS GROUP IS A
LEADING MANUFACTURER AND SUPPLIER OF AGRI MACHINERY PRODUCTS,
CONSTRUCTION & MATERIAL HANDLING EQUIPMENT, AUTO SUSPENSION AND
ANCILLARY PRODUCTS AND RAILWAY EQUIPMENT.

(ESCORTS AGRI MACHINERY COMPONENTS PLANT AT FARIDABAD)

A pioneer of farm mechanisation in India, Escorts Agri Machinery (EAM) was launched in 1960. The
company manufactures tractor under the brand names of Escort, Farmtrac and Powertrac. EAM
consists of four manufacturing plants that cover an area of 134,000 sq.m. The company also has a
plant in Poland, which is a 100% subsidiary and functions in the name of Farmtrac Europe.

Escorts Group

Type

Public Limited

Industry

Engineering Conglomerate

Founded

1960

Founder(s)

Hari Nanda and Yuri Nanda

Headquarters

Faridabad, India

Area served

Worldwide

Key people

Rajan Nanda (Chairman and Managing Director) and Nikhil Nanda

(Joint Managing Director)

Tractors, crop solutions, cranes, loaders, shock

Products

absorbers, struts, steering components, brakes for

railways, couplers

Employees

6,000 (2011)

Website

www.escortsgroup.com

Historical Background
Escorts came into being with a vision and a mission. A vision that led two brothers
YUDI NANDA and HARI NANDA to branch out from their familys prospering transport
business and institute ventures that were to become the foundation of ESCORTS Ltd. Escorts
agents limited was born at Lahore on 17th Oct, 1944 with YUDI NANDA as managing director
and HARI NANDA as the chairman. After that owning to the opportunities lying in the Indian
villages Escorts (Agricultural Machines) Ltd., was launched in 1948 with YUDI NANDA as the
director. Tragically, he died in an accident in 1952. Then Escorts Agents Ltd . And Escorts
(Agricultural Machines) Ltd. Was merged in 1953 to create a single entity Escorts Agents Pvt.
Ltd. The companys incorporation in its present name, Escorts Ltd. was effected on 18th January
1960.

Having initially started with a franchise for vesting house domestic appliances, Escorts has come
a long way in manufacturing and marketing a large range of products. It has pioneered farm
mechanization in India through import and distribution of agricultural tractors.

The manufacturing operations commenced in 1954, and since then the following range of
products have been introduced in the country:

1954: Piston rings and Cylinder liner

1960: Pistons

1961: Assembly of tractors

1962: Motorcycles and railway couplers

1963: Automotive shock absorbers

1965: Agricultural tractors under Escorts brand name

1969: Agricultural tractors under Ford brand name

1971: Industrial and construction equipment

1979: Excavator loaders

1981: 100cc motorcycles

1985: Electronic PABXs

1991: Harvester combines

1992: VSAT Satellite Communication System

1993: Mobile communications

1995: Fork lift trucks

1996: Disengagement of joint venture collaboration with New Holland and launch of
FARMTRAC Tractor.

The single word completely described the character philosophy and success of the company,
which grew from a small beginning to one of the ever-changing dimensions. For five decades
Escorts has been in the core sectors like Agriculture, Transportation, Construction & Resources
for Engineering change through optimum product performance. From its inception Escorts has
firmly believed that success inspiring on being close to the customer thus every corporate
endeavor addresses it to end used, adjusting to ever changing markets.At every step of the way,
Escorts had inducted the latest technology by forming alliances with the worlds most advanced
Engineering and Electronic companies, constantly adopting their technology according to Indias
need and situation. To make sure the finished product delivers on its promise the company had
created an extra-ordinary distribution and service network that stays with the customer.
Escorts came into its own with a far reaching vision for the future to stay over close to the
customers with products made in India to international standards. The source of Escorts
consistent growth is commitment and contribution to the core needs of the country. Escorts have
firmly believed that success depends on being close to the customers. As early as in 1944 while

others were concentrating on selling their goods .Escorts sought to Escorts its merchandise
right up to the customers doorstep. This meant staying close to the customer, understanding their
needs, giving them a product that met these needs ensuring that it worked smoothly thereafter.
Today with Mr. Rajan Nanda as a Chairman and Mr. Anil Nanda as a ViceChairman the ideals have not changed. Thus, every corporate endeavor addresses to the end
users and the ever-changing market, substantial man-hours are being devoted to planning a new
range with the objective of consistently offering greater value to the customer.
In every area we touch our task has always remained one of engineering change
Rajan Nanda. In every step, Escorts has induced the latest technology to make products that are
not merely better but those meet international standard. For Escorts, these are two benchmarks
of

industrial

achievements,

the

distinct,

undisputed

edge

of

technology

and

the

internationalization of business.
In five decades Escorts has grown to become one of the top industrial conglomerates in the
country

FIVE DECADES OF ENGINEERING CHANGE

THE DECADE OF CREATION: 1944-1954

The launch of Escorts Agents Pvt .In Lahore and setting it all up again in Delhi after the
countrys partition .The beginning of an industry legend, with a tractor franchise, followed by
Indias first institute of farm mechanization and the companys first industrial venture, Goetze
(India) Ltd., at Patiala, in equity collaboration with Goetze of Germany.

THE DECADE OF AUTOMATION: 1955-1964

Escorts goes public. A full-fledged manufacturing orientation takes roots with the
commencement of Escorts own brand of tractors and next major field of operation: motorcycles.
The company joins hands with Mahle to produce Indias most advanced pistons.

THE DECADE OF CONSOLIDATION: 1965-1974

The foundation of the Ford-Escorts alliance for Indias finest tractors, soon to make the
group the largest selling tractor manufacturing .Escorts Employees Ancillaries Ltd., a unique
venture in industrial democracy, comes into being.

Escorts receives FICCI Award for outstanding contribution to Indian agriculture .The
company crossed national boundaries with its first export of 400 tractors to Afghanistan, won in a
global tender. A triumph of Escorts quality and competitiveness, this was perhaps the worlds
largest ever commercial airlift of its kind.

THE DECADE OF DIVERSIFICATION: 1975-1984

One with Knorr Bremse follows an epoch-making alliance with JCB for Indias first
Excavator-loaders for railway breaks. With the Yamaha collaboration, Escorts become the
countrys largest motorcycle manufacturer. Acknowledged leadership in automotive ancillariesMahle pistons and Goetze rings .

THE DECADE OF GLOBALISATION: 1985-1995

Escorts enters into joint venture with buy back arrangement with Class (Harvester
Combines) and Herion (Hydraulic valves) providing an entry to world markets. A tie-up with
Faun, powers the company to supremacy in hydraulic mobile cranes. Escorts fights an epic battle
against a corporate raid, the ultimate victory providing the unshakable confidence of the
companys small shareholders countrywide. Escorts Heart Institute commissioned, hailed as
among Asias most advanced. Escorts turnover crosses Rs. 15 billion. In the sunrise telecom
sector, alliances with JS telecom, a Bosch company, and Hughes Network systems, world leaders
in VSAT networks.

THE DECADE AHEAD: 1996

The Mission is Globalization and the emphasis will be on core sector investments. Escorts
is going in for a global network and for mega projects in the 21st century.

ESCORTS: RESTRUCTURING
Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its
inherent strengths, a strong presence in the Core Sector providing complementary product lines
and a vast marketing network; combining them with Indias intrinsic cost advantages to become a
global source point for high value engineering products.
Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its
inherent strengths, a strong presence in the Core Sector providing complementary product lines
and a vast marketing network; combining them with Indias intrinsic cost advantages to become a
global source point for high value engineering products.
In order to meet the challenge of the future and to leave an indelible mark on industrial scenario,
Escorts has restructured the group along 4 business lines, each headed by an independent CEO.
The business groups are as follows:-

1) Agri Machinery Group

2) Construction Equipments
3) Automotive Ancillaries
4) Financial Services

ESCORTS THE GROUP INFRASTRUCTURE

The flagship of the Escorts group is Escorts Ltd. in the words of Mr. Rajan Nanda. Chairman
Escorts Limited., in the last 50 years Escorts has been more than merely one of Indias largest
Engineering Companies. It has been a prime mover on the industrial front; at every stage
introducing products and technologies that helped take the country forward in key areas. Today as
the nation engages in its most momentous economic transformation ever, we are once again
adapting ourselves towards being catalysts for qualitative growth by Engineering Change with a
global perspective.
The group infrastructure comprises:23 main associates/subsidiary companies
1) 12 manufacturing locations
2) A full-fledged R&D facility
3) Nearly 10,000 employees
4) 24 regional marketing offices
5) Nearly 500 ancillaries forming the vendor base
6) 4 financial services companies
7) Asias best training institute of Farm Mechanization with 100 acre demonstration farm.

EDDAL Escorts Dealer Development Association providing management and financial support
to dealers .

THE ESCORTS GROUP

THE FLAGSHIP COMPANY

o Escorts Limited

OPERATING DIVISIONS
o Agri machinery division
o Engineering division
o International business division

SUBSIDARY COMPANIES
o Escorts construction equipment Ltd. (cranes, exvators, truck loaders)
o Esconet services
o Escorts Automotives(Investment)
o Escosoft technologies
o Escortal tele communication ltd.
o Cellnext solutions
o Automatrix India
o Escorts heart institute & research center
o Escorts hospital & research center
Medical care (erstwhile division of Escorts lived off 100% subsidy)

ASSOCIATE COMPANIES
o India Ltd. GOETZE (India) Ltd.
o GOETZE TP (India) Ltd.
o GOETZE (India) assets management Ltd.
o Escorts securities ltd.
o Escorts Mahle Ltd.
o Escorts Employees Ancillaries Ltd.
o Escorts Finance Ltd.
o IFS India Escorts
o Hughes Escorts communication ltd.
o Carraro (India) ltd.

ESCORTS GROUP CORE BUSINESSES

BUSINESS GROUPS

PRODUCTS

Agri-Machnary

Tractors

Construction equipment

Earth moving Machines

Vibratory Rollers

Material Handling Equipments

Pistons, Piston Rings

Aluminum Cylinders

Shock Absorbers

Carburetors

Magnetos

Clutches

Air Brakes

Couplers

Electro-Pneumatic Brakes

Shock Absorbers

Cellular Telephone services

VSAT Services (satellite communication system)

Automobile Financing

Consumer Finance

Mutual Funds

Fixed Deposits

Machining

Painting

Assembly

Engine PU

Transmission PU

Rear Axle PU

Assembly/tractor PU

Personnel & HRD

Finance

Manufacturing Engineering

Plant Engineering & Machine Maintenance

Information Systems

Automotives

Railways

Telecom

Financial Services

Manufacturing Facilities

Product Units(Pus)

Departments

THE PLANT
The plant is equivalent with the following units: Engine Productive Unit (EPU)
Transmission Productive Unit (TPU)
Rear Axle Productive Unit (RAPU)
Tractor Productive Unit (TPU)
Paint Shop
Now transmission productive unit and rear axle productive unit have been merged and now it is
one productive unit known as transmission and rear axle productive unit.
The plant is equipped with the following facilities:MACHINE SHOP : EPU, RAPU AND TPU have separate machine shops equipped with
several purpose machine (SPM) as well as Computerized Numerically Controlled (CNC
machine).

The different components machine in these shops with their respective

sections are listed below:
o Cylinder Head, Cylinder Block and Connecting Rod.
o Case Transmission.
o Center Housing & Trumpet Housing.
o Tool Room.
o Turning, CNC, Gear Cutting, Grinding & Heat Treatment.

In heat treatment shop following facilities are available:

o Gas Carbonizing, Hardening & Tempering
o Induction Hardening

Following facilities are available in the various productive units:

o Transmission assembly
o Rear axle assembly
o Engine assembly and testing
o Tractor assembly

PROPOSED IDEAS
Before coming to the select final project that is STUDY AND UPDATION OF PROCESS OF
CLYNDER BLOCK E 3-312, I had discussed various project ideas.
1. Time Study of process.
2. Inspection sector
3. Inventory and Storage.

Time Study of process

AIM: To study each and every process and find out the time period of each machine and
suggest idea to improve the system.
Reasons for Rejection
i)

It Is already given to another group of trainee

Inspection and Instrument

AIM: To Study the inspection Process and study Of Inspection Instrument.
Reasons for Rejection:
i)

Source Of Knowledge Is small.

STUDY AND UPDATION OF PROCESS OF CLYNDER BLOCK E 3-312

AIM: To Study the whole process and find out the factors which are help full to improve the
Quality and reduces the process timing.
i)

It covers Both Time Study of Process and Inspection and Instrument.

ii) Scope of Knowledge is more.

iii) It is needed because some Machine are Replace By new Machine and sequence is also
alter.

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
DUPLEX MILLING MACHINE
(SPM)
BSM-8
20
7mint

OPERATION DESCRIPTION

Rough and finish milling operation on

sump face and head face is occur on this
machine.
1. HEAD FACE:
Rough and semi finish milling operation
2. SUMP FACE:
Rough and semi finish milling operation

CUTTING TOOL DETAIL

Face milling cutter

Sump side
Diameter 500mm
Insert span 1203 THN/H13A
Head Side
Diameter 400mm
Insert span 1203 THN/H13A

Process Explanation
Milling:

It is a machining process in which the removal of metal takes place due to

cutting action of revolving cutter when the work is fed past it Revolving cutter is on a spindle
or arbour and the work (job), clamped on the machine table, fed past the same In doing so,
the teeth of the cutter remove the metal , in the form of chips from the surface of the work to
produce the desire shape.

DUPLEX MILLING MACHINE (SPM)

PROCESS:

This is a special purpose machine (milling).

In this machine only face milling operation occur.
Milling Operation occurs on head face and sump face.
The whole process is occurs in reference of DOWEL as shown in the diagram.

Reference of work piece also known as dowel

BRIEF DISCUSSION OF MILLING OPERATION

Milling is a basic machining process by which a surface is generated by progressive chip removal.
The work-piece is fed into a rotating cutting tool. Sometimes the work-piece remains stationary, and
the cutter is fed to the work. In nearly all cases, a multiple-tooth cutter is used so that the material
removal rate is high.
Often the desired surface is obtained in a single pass of the cutter or work and, because very good
surface finish can be obtained, milling is particularly well suited and widely used for mass-production
work. Many types of milling machines are used, ranging from relatively simple and versatile
machines that are used for general-purpose machining in job shops and tool-and die work (these are
NC or CNC machines) to highly specialized machines for mass production. Unquestionably, more flat
surfaces are produced by milling than by any other machining process.

Process Explanation:
Milling operations can be classified into two broad categories called peripheral milling and face
milling. Each has many variations. In the surface is generated by teeth located on the periphery of the
cutter body. The surface is parallel with the axis of rotation of the cutter. Both flat and formed
surfaces can be produced by this method, the cross section of the resulting surface corresponding to
slab milling, the axial contour of the cutter. This process, often called is usually performed on
horizontal spindle milling machines. In slab milling, the tool rotates at (Ns) fm some rpm while the
work feeds past the tool at a table feed rate in mm per ft. minute, which depends on the feed per tooth,
V As in the other processes, the cutting speed and feed per tooth are selected by the engineer or the
machine tool operator. As before, these variables depend upon the work material, the tool material,
and the specific process. The cutting velocity is that which occurs at the cutting edges of the teeth in
the milling centre. The rpm of D the spindle is determined from the surface cutting speed, where is the
cutter of diameter in [mm] according to: Ns = 1000 V/ p D

UP VERSUS DOWN MILLING

For either slab end or face milling, surfaces can be generated by two distinctly different
methods. Up milling is the traditional way to mill and is called conventional milling. The
cutter rotates against the direction of feed of the work-piece. In climb or Down milling, the
cutter rotation is in the same direction as the feed rate. The method of chip formation is
completely different in the two cases.
In up milling, the chip is very thin at the beginning where the tooth first contacts the work,
then it increases in thickness, becoming a maximum where the tooth leaves the work. The
cutter tends to push the work along and lift it upward from the table. This action tends to
eliminate any effect of looseness in the feed screw and nut of the milling machine table and
results in a smooth cut. However, the action also tends to loosen the work from the clamping
device; therefore, greater clamping forces must be employed with the danger of deflecting the
part. In addition, the smoothness of the generated surface depends greatly on the sharpness of
the cutting edges. In up milling, chips can be carried into the newly machined surface,
causing the surface finish to be poorer (rougher) than in down milling.
In down milling, maximum chip thickness occurs close to the point at which the tooth
contacts the work. Because the relative motion tends to pull the work piece into the cutter,
any possibility of looseness in the table feed screw must be eliminated if down milling is to
be used.

It should never be attempted on machines that are not designed for this type of milling.

Virtually all modern milling machines are capable of doing down milling and it is a most
favorable application for carbide cutting edges. Because the material yields in approximately
a tangential direction at the end of the tooth engagement, there is less tendency (than when up
milling is used) for the machined surface to show tooth marks, and the cutting process is
smoother with less chatter. Another advantage of down milling is that the cutting force tends
to hold the work against the machine table, permitting lower clamping forces. However, the
fact that the cutter teeth strike against the surface of the work at the beginning of each chip
can be a disadvantage if the work-piece has a hard surface, as castings sometimes do. This
may cause the teeth to dull rapidly. Metals that readily work harden should be climb milled.

MILLING TOOLS AND CUTTERS

A rotary tool-steel cutting tool with peripheral teeth, used in a milling machine to remove
material from the work-piece through the relative motion of work-piece and cutter .

Basic Operation:

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
HTC-630 & HTC 600 (SPM)
BMC-8 & BMC-16
30

PERATION DESCRIPTION
1. HEAD FACE
Finish milling operation
2. SUMP FACE
Finish milling
Drilling Hole milling-Reaming
of dia. 13H7 of 2 dowel
Drill Dia. 18.5
Drill two holes on L-pad of
Dia.10.2
3. CAP SEAT
Rough / finish milling operation

CUTTING TOOL DETAILS

1.T-Max Face milling cutter Radius 265.4-125-10
2.C.T. Milling Cutter
3.HSS T.S. Drill Tool of dia. 12mm
4.S.S. Hole Mill Tool of Dia. 12.7mm
5 Reaming Tool of Dia. 13H7

BRIEF DISCUSSION OF DRILLING OPERATION

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is
pressed against the work piece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the work piece, cutting off chips from what
will become the hole being drilled.
Classification of Drill:
Drills are manufactured in several different forms and sizes. They commonly used drills can
be classified in many ways, as follows:
1. According to the type of shank they carry:
a) Parallel shank
b) Taper shank
2. According to the type of Flutes :
a) Flat or Spade drills (parallel longitudinal flutes)
b) Twist Drills (spiral/ helical flutes)
3. According to the Tool Material:
a) High Speed Steel Drills
b) Carbide Tipped Drills

When inspecting various products around us we realize that the vast majority have several
holes in them. Holes are generally used either for assembly with fasteners such as bolts
screws and rivets each requiring a hole or to provide access to the inside of a part. Note for
example the number of rivets on an airplane s fuselage or the bolts in engine blocks and
various components under the hood of an automobile.
Hole making is among the most important operations m manufacturing. In automotive engine
production the cost of hole making is one of the largest machining costs. Drilling is a major
and common hole making process other processes for producing holes are punching and
various advanced machining processes.
Because drills usually have a high length-to-diameter ratio the next figure they are capable of
producing relatively deep holes. They are somewhat flexible however depending on their
diameter and should be used with care in order to drill holes accurately and to prevent the
drill from breaking.

TYPES OF TOOL
Furthermore the chips that are produced within the work-piece have to move in the direction
opposite to the axial movement of the drill. Consequently chip disposal and the effectiveness
of cutting fluids can present significant difficulties in drilling.
Generally the hole diameters produced by drilling are slightly larger than the drill diameter
oversize as one can note by observing that a drill can be easily removed from the hole it has
just produced. The amount of oversize depends on the quality of the drill and of the
equipment used as well as on the practices employed. Depending on their thermal properties
some metals and non-metallic materials expand significantly due to the heat produced by
drilling so the final hole could be smaller than the drill diameter .Also drilled holes may be
subjected to subsequent operations for better surface finish and dimensional accuracy such as
reaming and honing. Drills generally leave a burr on the bottom surface upon breakthrough
necessitating de-burring operations.
TWIST DRILL
The most common drill is the conventional standard-point twist drill Fig. (a) the main
features of which are the point angle lip-relief angle chisel-edge angle and helix angle. The
geometry of the drill tip is such that the normal rake angle and velocity of the cutting edge
vary with the distance from the center of the drill.

Generally two spiral grooves flutes run the length of the drill and the chips produced are
guided upward through these grooves. The grooves also serve as passageways to enable the
cutting fluid to reach the cutting edges. Some drills have internal longitudinal holes through
which cutting fluids are forced improving lubrication and cooling as well as washing away
the chips.
Drills are available with a chip-breaker feature ground along the cutting edges. This feature is
important in drilling with automated machinery where disposal of long chips without operator
assistance is necessary.
Other Types of Drills.
Several types of drills are shown in the next figure.

A step drill produces holes of two or more different diameters. A core drill is used to make an
existing hole larger. Counter-boring and countersinking drills produce depressions on the
surface to accommodate the heads of screws and bolts. A center drill is short and is used to
produce the hole at the end of a piece of stock so that it may he mounted between centers in a
lathe between the headstock and the tailstock. A spot drill is used to spot to start a hole at the
desired location on a surface. Spade drills have removable tips or bits and are used to produce
large and deep holes. They have the advantages of higher stiffness because of the absence of
flutes in the body of the drill ease of grinding the cutting edges and lower cost. Crankshaft
drills have good centering ability and because chips tend to break up easily these drills are
suitable for producing deep holes.

Twist Drills
Twist drill is the most widely used in the modern drilling practice. It consist of a cylindrical
body carrying two spiral flutes cut on it.

Parts of Twist Drill

Three main components are the:
Shank
Body
Point
1. SHANK
This is the portion which is clamped to provide the drive. Straight shank for
drill up to . Shank is equal to body diameter. Above , shank can be
tapered or reduced.
2. BODY
a) Flutes - Helical grooves cut around the body which form the cutting edges
Allow coolant to flow to the cutting edge
Allow chips to be withdrawn
b) Margin- Narrow raised section of the body. Provides full body to hole support
to help keep it aligned as it drills.
c) Body clearance - Reduced section of the drill between the flutes and margin.
Used to reduce friction between drill and workpiece
d) Web- Thin section in the center of the drill which forms a core for the drill.
This feature increases as it extends to the shank. Forms the chisel edge of the
drill.
3. POINT - Chisel edge of the drill.
a) Lips
b) Cutting edges

DRILLS MATERIALS
The two most common types are
1) HSS drills
i) Low cost
2) Carbide-tipped drills
ii) High production and in CNC machine
Other types are
Solid carbide drill, Tin coated drills, carbide coated masonry drills, parabolic drills, split point drill.

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
HTC-600 & Yasda (SPM)
BMC-11
40

PERATION DESCRIPTION
1. NAME PLATE SIDE
Rough/ Finish Milling Drill/TAP
of M-14
2. TAPPET COVER SIDE (TCP)
Rough/Finish Mill
Rough/Finish Bore of Dia.36H8
(3 holes)
3. TIME GEAR SIDE (TGC)
Mill Water impeller seat Drill of
Dia. 5

CUTTING TOOL DETAILS

1. STD Facing Milling Cutter R 265.4
2. End Milling Tool of dia. 40mm & 50mm

3. STD H.S.S T.S. Drill of dia.5*8

4. Finishing Bore Bar of dia. 36H8.

5. Finishing Bore Bar of dia. 36H8.

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
CNC DUPLEX MILLING (BM-211)
BSM-11
50
6 Minute

PERATION DESCRIPTION

TIME GEAR SIDE

a)Rough/finish mill

BELL HOUSING SIDE

a) Rough/finish mill

CUTTING TOOL DETAILS

TIME GEAR SIDE (UNIT A)
a) STD Centring plug ISO 50 x 60 500
cutter (widia number 80504021)
b) Face milling cutter 500

BELL HOUSING SIDE (UNIT-B)

a) STD Centring plug ISO 50 x 60 500

cutter (widia number 80504021)
b) Face milling cutter 500

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
WEB & NTCH MILL (BM-147)
BSM-6
60
6 Minute

PERATION DESCRIPTION

Plunge mill web thickness & 4

notches on cap seat

CUTTING TOOL DETAILS

TEF-2545 milling arbour

TEF 2486 HSS notch milling cutter 80
x 40H x 5D11
TEF-2490 of spacers
TEF half side and Face milling cutter RHhmt No. ( )
TEF half side face milling cutter L.H.hmt No. BM-147-9401-39

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
OIL GALLERY SPM(M348)
BSD-13
70
7:00 MINT

PERATION DESCRIPTION

Drill oil gallery hole from Crank to

Cam bore of 9 x 7- 4 holes.
Drill from Crank to Idler Bore of
6.81 hole.
Drill hole on Sump face of 15 1 hole
Drill holes on Tappet cover side of 9
4 holes
A drill on Head face side of 7 1 hole

CUTTING TOOL DETAILS

H.S.S. T.S. Drill 15x 350FL x 450
OAL (M35)TIN coated MT-2

H.S.S. Drill 6.8 x 195FL x 250OAL

(M35) tin coated MT-1

H.S.S. TS drill 7 x 300FL x 350OAL

(M35) Tin coated MT-1

H.S.S. TS Drill 9 x 195FL x 295OAL

(M35) Tin coated MT-1

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
SNCH-11 & HMC-5008
BMC-7 & BMC-9
120
28.8/25.5

PERATION DESCRIPTION

CUTTING TOOL DETAILS

BELL HOUSING SIDE

Drill Oil Gallery Of 14

TAPPET COVER SIDE

Drill/Tap M10-6 hole, M12-3hole,
Drill of 14-1 hole.

NAME PLATE SIDE

Drill of 12.5 hole
.

STD twist Drill 14 x 410 OAL MT-1

STD twist Drill 14 x 223 OAL MT-1
STD Drill 9 x 175FL x 275OAL MT-1
STD Drill 11 (MT-1)
STD Drill 10, 12, 12.5

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
HEAD FACE DRILL(E-363)
BSD-14 ALT:- RADIAL DRILL
90
4.10 MINT

PERATION DESCRIPTION
HEAD FACE
Drill 12-14 holes
Drill 14.5-2holes
Drill 18.5-2 holes
Drill 12-14 holes
Drill 14.5-14 holes
Drill 5-4 holes

CUTTING TOOL DETAILS

STD T.S. Twist Drill 12h8 x 225 OAL
(Tin coated with M35 HSS material )
STD Core Drill 14.5 x 212OAl
(Tin coated with M35 material)
STD Core Drill 18.5-233OAL
ALT Drill
STD Core Drill 14.5 MT-2
STD Drill 5

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
2 WAY MULTIDRILL SPM (Y-1643)
BSD11
100
2.23

PERATION DESCRIPTION
TIME GEAR SIDE
Drill 6.8-17 holes
Drill 14-4 holes
Drill 7-1 holes
Drill 8.5-2 dowel
BELL HOUSING SIDE
Drill 10.2-10 holes
Drill 12-2 holes

CUTTING TOOL DETAILS

STD H.S.S. Twist Drill
Dia. 10.2 x 116FL x 197OAL
Dia. 9 x 107FL x 188OAl

STD H.S.S. T.S Twist Drill (MT-1)

Dia. 14 x 108FL x 189 OAL
Dia. 12 x 101FL x 182 OAL

TET-2272
H.S.S. S.S. Twist Drill 6.8 x 156OAL

TET-6367
H.S.S. S.S. Twist Drill 7 x 156OAL

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
MULTIDRILL SPM (MD-419)
BSD-10
110
5:00 MINT

PERATION DESCRIPTION

SUMP FACE
Drill of 8.5- 10 holes
CAP SEAT FACE
Drill 14 & Counter Drill 16.5-8
holes
HEAD FACE
Tap M14-12 Holes

CUTTING TOOL DETAILS

STD H.S.S. TS Twist Drill 6.5 x 181
OAL MT-1
STD H.S.S. TS Twist Drill 14 x 223
OAL MT-2
STD H.S.S. TS Twist Drill 16.5 x 223
OAL MT-2
Alternate
STD H.S.S. TS Drill 16.6 x 223 OAL
MT-2

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
TAPPING MACHINE(RADIAL DRILL)
BTM-1
130
14:00 MINTS

PERATION DESCRIPTION
SUMP FACE
Tap M10-10 holes
Tap M20-1 hole
L-pad Tap M12-2 holes
TIME GEAR SIDE
Tap M8-19 holes
Tap M16-4 holes
Dia.5-1 hole
BELL HOUSING SIDE
Tap M12-10 holes

CUTTING TOOL DETAILS

STD Machine Tap
M10 x 1.5 Type C
M12 x 17.5 Type C
M16 x 2 Type C
M20 x 1.5 Type C
M8 x 1.25 Type C
M14 x 2 Type C

Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Air Cleaning & Cap Fitting

PERATION DESCRIPTION

CUTTING TOOL DETAILS

Simple Machine working

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA

Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Rough Boring SPM
BSB-6
140
10.75

PERATION DESCRIPTION
ROUGH BORE OF
a) Crank bore
b) Cam bore
c) Idler bore.

CUTTING TOOL DETAILS

TFE-6091 Boring Bar for Crank Bore.
TET-2259 T-max Facing Tool L-H
TET-2260 T-max Facing Tool R-H
TEF-6092 Boring Bar for Can Bore
STD-T Max Cartridge R437-9-1214-11
STD- T Max Insert TPUN 110308-H20

TEF-6341 Boring Bar for Idler Bore

Insert TPMR 160308X10
CHF INSERT CCMT 060204 UR

UNIT-B(BHS)
TEF-6094 Boring Bar Crank Bore
STD T max Cartridge R437.9 1320.16
STD T max Insert TPUN160308-H-20
TEF-6095 Boring Bar for LAN Bore

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Lime Boring SPM(YB017& Y3304)
BSB-5
150
4-9 Min

PERATION DESCRIPTION

FINISHED / SEMI FINISHED BORE

OF
a) Crank Bore
b) Cam Bore
c) Idler Bore

CUTTING TOOL DETAILS

TET-9180 Boring Bar for Crank Bore
TET-3244 Boring Tool
STD T-Max Catridge R-437.9-1214.4
STD T-Max Insert TPUN 110308 HIP
TEF-3237 Boring Bar for Cam Bore
TET-3242 Boring Tool
STD T-Max Cartridge 1-1481-11-0602
STD T-Max Insert CCMT 060204-41p
TEF 6200 Boring Bar for Idler Bore
STD Micro Bar Unit M3A2F40

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Lime Boring SPM(Y3304)
BSB-8
180
4.46 Min

PERATION DESCRIPTION

BORE OF
a) Sank Bore
b) Cam Bore
c) Idler Bore

CUTTING TOOL DETAILS

TEF-3395 Boring Bar for Crank Bore

STD T-max U Fine Boring Unit
L-148C-13-1102
STD Insert TCMT 110208 HIP
TEF-3237 Boring Bar for Cam Bore
STD T-max U Fine Boring Unit
L-148C-13-D602
STD Insert CCMT 060208 HIP
ALT-CCGX 060204 Grade ALH-10
TEF-6200/1 Boring Bar for Idler Bore
STD T-max U Fine Boring Unit
L-140C-31-0602
STD Insert CCMT 0602084P

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Dowel Hole SPM
FB-668 (BS7-9)
200
3.35 Min

PERATION DESCRIPTION
BELL HOUSING SIDE
Bore Dia. -13h7-2 Dowel Holes.
Hole Mill/Ream Dia. 13h7-2 Dowel
Holes.

TIME GEAR SIDE

Bore Dia. -10h7-2 Dowel Holes.
Hole mill/Ream Dia. 10H7-2 Dowel
Holes.

CUTTING TOOL DETAILS

TEF-6529 Tool Holder For Dia-13H7

TEF-6500 Boring Bar For Dia-13H7
TEF-6542 Tool Holder For Dia. 10H7
TEF-6449 Boring Bar For Dia. 10H7
TEF-6523 Locating PIN for B.H.S.
Insert STD CCMT 060204 THM
TEF-6524 Locating PIN for T.G.S.
ALTERNATE On Radial Drill
STD Collect MT-1 For Q.C.C
STD H.S.S Reamer Dia-10H7 15.5445
TET-2053 H.S.S H Mill Dia. 12.7H9
STD H.S.S Reamer Dia. 13H7 155445

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
Tappet-SPM (Y-3505)
BSD-16
190
8:00 Min

PERATION DESCRIPTION

End Mill Drill

Hole Mill
Ream 24H8-6
Tappet Hole

CUTTING TOOL DETAILS

TET-6671 JIG Bar For Drill 22.5

TET-6620 End Mill 36 x 65FL x 157OAL MT-3
TET-6672 JIG Bar For Hole Mill

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
VTC-3 & VTC-5

PERATION DESCRIPTION

Drill Oil dip stick hole.

Drill/Tap M8-2 holes Time Gear Side.
thru Hole Mill/Ream dia.18H8-2.

CUTTING TOOL DETAILS

STD Tap Driver for M8(MT-2)

STD Machine Tap M8 x 1.25 Type 'C'.

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
VCRT MACHINE G CENTER(LMV55)

PERATION DESCRIPTION

Finish milling head face.

Finish Bore linear Bore.
Hole Mill/Ream Dia.20H8-2 Dowel Holes.
Drill Dia. 10-3 Holes.

CUTTING TOOL DETAILS

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
INSPECTION AND CLEANING

PERATION DESCRIPTION
INSPECTION PLACE

CLEANING MACHINE

CUTTING TOOL DETAILS

ESCORTS LIMITED COMPONENT PLANT

CASTING AREA
Part Name
Part Number
Machine Name
Machine Number
Operation Number
Cycle time

D10025590B
MANUAL BUSH PRESSING MACHINE

PERATION DESCRIPTION

Fit 4 Cam Bush .

Bush

CUTTING TOOL DETAILS

OPERATION FINAL INSPECTION

S.NO.

DISCRIPTION

DIMENTION

INSTRUMENT

GAUGE

1.

Tappet Bore Dia.

24H7

Dial Bore Gauge

STD

2.

3-Holes on Tappet Cover side

36H8

Dial Bore Gauge

STD

3.

Cam Bore Dia.

56H7

Dial Bore Gauge

STD

4.

Thrust Bearing Dia.

110+0.12

Plate Gauge

TEG-3249

5.

Thrust Face Thickness

42(-.02or-.009)

Width Gauge

TEG-2250

6.

Alignment of Cam Bore

0.02

Mandrel

TEG-6244

7.

Crank Bore Dia.

91.055/91.085

Dial Bore Gauge

STD

8.

Alignment of crank Bore

0.02

Mandrel

TEG-6202

9.

Idler Bore Dia.

32H7

D.B.G.

STD

10.

Dia. of Linear Bore

120H7
121H7
130H7

Dial Bore Gauge

STD

11.

Depth of C'Bore From Head Face

11(+0.02)

Flush pin Gauge

width Dial

TEG-6265

12.

Position of Crank, Cam, Idler Bore Depth

Of Thrust Face position of linear bore

Gauging fixture

TEG-6046

13.

Linear Bore Stud Hole Clearance

Functional Gauge

TEG-6393

TECHNICAL CONDITIONS

All oil galleries to be checked with dia.3mm wire for through

holes.
All oil galleries to be cleaned and blown through by air under
pressure.
Water impeller seat to be checked for fouling of impeller with
side walls.
Check all liner bore for fouling of linear will wall.
Check all Threaded holes for threading depth.

ISHIKAWA CHART
Diagnose the cause of failure of Cam, Crank, Bore .

CONCLUSION
Its give me better honour and privilege to conclude the Project report on
STUDY AND UPDATION OF PROCESS OF CLYNDER BLOCK E 3-312
has been presented in a very concise and lucid manner i indeed have given
commitment to the development of my project.
The aim STUDY AND UPDATION OF PROCESS is to get knowledge of all
process occurs in this cylinder block.
This project help me out to get a lot of information not only the processes occur
in this line but also different fields like inspection and quality control unit and it
also tell me the human relationship which is needed in Between managers, team
leaders and employ of the company.
It also help me to get knowledge about the tools and there different-different
properties and types.
Some new things which i learned from this company are
Use of different different gauges.
How to inspect the job after each and every inspection
How to manage the machine if there is any problem arises in the machine
Tools specification and its inserts characteristics.
How to manage the task in the given interval of time.

THANKYOU