BEML

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CONTENT
1. PLATE SHOP
2. FABRICATION SHOP
3. MACHINE SHOP
4. HEAT TREATMENT SHOP
5. GEAR SHOP
6. MACHINE SHOP 2
7. TOOL ROOM
8. DOZER ASSEMBLY
9. EXCAVATOR ASSEMBLY
10.DEFENCE HANGER
11.RESEARCH AND DEVELOPMENT

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PLATE SHOP
OPERATIONS INVOLVED;
 Shearing
 Rolling
 Straightening
 Cutting
 Bending
 Drilling

Shearing machine
The shearing machine was mainly used to cut the flat metal plates into two (or) more
plates into of different sizes, shapes, as per the required dimensions.

Straightening machine
The machine are used in process of straightening the deformed metal plates

Mechanical press brakes

These pressing machine are used to bending the metal plates of different types and
punching pieces

Flame cutting machine

 These are cutting machines mainly used to cut the metal plates.
 These machine traces the and cut the same part in the work piece.
 Here oxy-acytelne gas mixture is used to cut the metal plates.

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Vertical drilling machine

 It is used to drill holes in the metal plates of required diameter.
To drill different holes different types of drill bits are used.

Tool piece; drill bit

Work piece; metal plates

Coolant; liquid coolant (oil 30% , water 70%)

Sub merged arc welding

 These machine are used in the process of joining two or more metal parts
 These machine are uses filler materials (copper coated mild steel)
 These depends upon the thickness of the plates, setting current and voltage is
required.

Plasma cutting
 It is a process cuts through electrically conductive material by means of an
accelerated jet of hard plasma.

FABRICATION SHOP

OPERATION INVOLVED;
 Welding
 boring

Welding portion; horizontal,vertical,down head, outer head, pipe welding

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Stages of fabrication;
 set up
 layout
 machining operation
 welding

 assembly

Tungsten inert pas welding (TIG)

Inside gasses used to outer come oxidation

Piping section;
 manufacturing of hydraulic pipes using welding process
 here casted parts of the hydraulic pipes were joined by tig welding process

MACHINE SHOP

OPERATIONS INVOLVED;
 drilling
 boring
 thread cutting
 rolling
 shearing
 radial drilling
 taper turning
 milling

Machines used;
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 HMC ( CNC )
 VMC ( CNC )
 Horizontal milling machine
 Vertical milling machine
 Turrent lathe
 Drilling machine

HMC;
Hmc is also known as milling relief on rotatory cutters to remove metal from workpiece
.The spindle is parallel to the ground flore

VME;
It is a type of cnc machine typically enclosed and made often used for metal they are
usually very price and very expensive

The machine is mainly uses cnc controller made by SIMENS (or) FANUC MACHINE

FACE MILLING

 Multipoint cutting tool is used

 32 cutting tips
 Clockwise down milling
 Counter clockwise up milling

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RADIAL DRILLING MACHINE

Counter bore and taper operations work done by vertical machining entires

SBCNC 35
 Here turning, boring, facing, milling, keyway opeations can done with a error of
0.02
 It has been named SBCNC 35 new slant bed
 Here workpiece and speciemen placed on slant bed

TURRENT LATHE
Except thread operation all other operations can be done here

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HEAT TREATMENT
OPERATIONS INVOLVED
 Annealing
 Normalizing
 Hardening
 Quenching
 Gas carburizing
 Nitriding

To increase the material properties heating of 930 c

Hardening; temperature<820 finite furnace

Temperature>820 furnace

Quenching; sudden wailing of heated metal will increase the hardening of that material , the
exhaust gas co is burnt completely before leaving into the atmosphere

INDUCTION HARDENING
 600 V operated frequency 4kh
 Cooling water quantity 74lit/min
 3-8 bars of cooling pressure/min

MACHINE SHOP 2

Surface grinding; the magnetic holder holds the workpiece

 Maximum dia of 1000mm

 Maximum grinding length 520mm
 Main motor (HP 30)

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HEAVY DUTY PLANE MILLER

 3 tool heads
 X,Y,Z axis tool movement
 Minimum rpm 25 maximum rpm 900

HORIZONTAL BORING MACHINE

 500-700 bore can be done using HSS tool
 Spindle diameter 180mm all operations done here
 Carbide tool used spindle speed 4-S 900

SAW CUTTING
 Only cutting operation done here
 HSS cutting tool is used
 It is uni continuous cutting tool with constant speed

SKODA MACHINE
 Operations done here boring, drilling, chamfering etc…
 X axis 3mm, Y axis 8 mm,Z axis 2mm

GEAR SHOP
OPERATIONS INVOLVED
 Hobbling
 CNC shaping
 Gear grinding (tooth)
 Shaving
 Vertical and horizontal broaching

MACHINES USED; turning, tapering, thread cutting, grooving operations done

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HORIZONTAL BROCHING MACHINE

Here internal gear cutting and internal bore tapper bore is done

VERTICAL BROCHING MACHINE

Multipoint cutting tool is used for mainly mass production of materials tool used is
HSS cutting tool

SHADING MACHINE
Both internal and external gear cutting is done

 No of teeth’s on cutter is 34

SHAVING MACHINE
To get a clean surface finish shaving machines are used

TYPES OF CURVES
 Cylindrical curve
 Involute curve
 Probe
 Used granite in checking matching to overcome bend

RAPID 1500 CNC GRINDING MACHINE

It is used for shaving surface finishing and all operations done at a time

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TOOL ROOM
Here transmission assembly takes place

There are two types of transmission

1. Hydraulic transmission
2. Mechanical transmission
 Hydraulic transmission are controlled by transmitting oil
 Mechanical transmission are controlled by mechanical linkage

DOZER ASSEMBLY

OPERATIONS INVOLVED
In this section all parts of the dozer equipment’s are assemble here

Assembly parts includes

 Front idler

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 C-clamp
 Track shoe
 Final drive
 Blades
 Lift cylinder
 Transmission system
 Engine….etc

Examples; BD355, BD60, BD50, BD475, are the sum of dozer assembly in this sector

 After completion of assembly testing will be done

 In testing if any problem were found the development of team will make several design
changes to overcome this problem
 The testing of products will be made until dozer production were fully produced to the
working condition

EXCAVATOR ASSEMBLY

Here high end excavator parts are being produced

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Sum of the examples of dozer excavators produced in high end excavator assembly are

EXCAVATOR DRIVE HORSE POWER

BE700-IN Engine 404hp

BE1000-IE Motor 542hp
BE1250 Engine 670hp
BE1600 Engine & motor 404+404hp
BE1800 Diesel engine 470+470hp

UNDER CARRAIGE MAIN PARTS

1. In track frame
2. Track roller
 Carrier roller
 Idler
 HIC (hydraulic idler coushning)
3. RH Track frame
 Track roller
 Carrier roller
 Idler
 Hic
 Track shoe assembly
4. Centre frame
 Several joints
 Hydraulic turning joint
5. Rooling frame
 Engine
 PTO
 Hydraulic pump
 Main pump

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 Lubrication pump
 Axial piston pump
 Control valve
 Control piping

Attachments ;

PARTS
QUENTITY
Boom cylinder 2
Boom 1
Bucket cylinder 2
Bottom pump cylinder 2
Arm cylinder 2

MOUNTING AND DYNAMIC PARTS OF THE EQUIPMENT

 Final drive
 Planetary gear box
 Propelled by hydraulically operated development axial piston bidirectional travel
motor
 All the operations are controlled pilot joysticks through pilot pump
 Closed loop swing system
 Open loop swing system
 Engine and hydraulic pumps were synchronized by load limiting controlled

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DEFENCE HANGER

Here some of the defiance equipment’s such as TETRA, ARRV,ARV,etc are produced

TETRA MODELS

Drive system; 4*4,6*6,8*8,10*10 Service

The vehicle used for handling ground support equipment’s transportation of peoples,
food, eqipments on

MOUNTED GUN SYSTEM (MGS)

Indigenously designed developed & manufacturing a shining example of make in india

Armament ; 155mm gun , 52 calibrate

Vehicle ; BEML TETRA 8*8 vehicle

Range with HE ERFD\BB ; 38KM (BMCSZ-6)min

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SAILENT FEATURES
 Modular design
 Commonality with existing arty gun platform
 Excellent shoot capacity
 Gps aidded INS
 Accurate target engagement at long time
 Hydraulic operated system

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BEML MBPV 4*4

CHASSIS FEATURES
 High power water cooled engine
 Fully automatic transmission
 Backbone chassis
 Semi articulated axle
 Run flat tyres
 Combination suspension
 Color transmission TFT LCD
SL NO PARAMETER UNIT VALUE
1 Vehicle GVW Kg 10000
2 Engine power Kw 235
3 Power to weight Kw\t 23.5
4 Highway speed Kmph 100
5 Troops No’s 10
6 Gradient Deg 30

SAILENT FEATURES
 Vehicle body is fully encapsulated to provide armor protection to occupants at all points
 All wheel drives for max traction
 Swinging half axles for better cross country operation
 80kmph maximum speed
 Fail safe air brake system
 High ground clearance for cross country operation
 Can wade through water upto 1000mm
 Trench crossing ability (vertical steps)400mm

 8 passanger + 2 crew

ENGINE ; water cooled 4-stroke (235kw) inline , turbo-charged after cooled ,CRDI diesel
electronically controlled

TRANSMISSION ; automatic transmission (6 speed forward & 1 reverse )

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AXLE ; swing half axle , separately sprung (front & rear )

SUSPENSION;
FRONT; combination of torsion bar & telescopic shock absorber

REAR ; combination of air bellows with coil spring & telescopic shock absorber

PROTECTION LEVEL;

BALLISTIC PROTECTION ; NATO STANAG 456 LEVEL

BLAST PROTECTION ; 2 NO HE36 hand grenade at a time under belly

BRAKES; drum brakes ,pneumatically assisted cam type brake unit, ABS for separate brake
system , exaust barkes

RESEARCH AND DEVELOPMENT

POWER LINE LABORATORY

 Transmission assembly (power transmission through gear was engaged

 Here they are using mechatronics technology
 The control program were developed according to the operation required
 Test facilitation
 Cylinder test
 Pump test
 Axle test
 Transmission controlled assembly involves mechanical power transmission through gears
two types of gear system
 Main gear box axle; it has two forward and two reverse gear control in 8*8 tetra
 Auxiulary gear box ; it is an additional gear box both to geather speed control
 Tatra truck; it has 8 power transmission points, it has synchronizing for 2nd ,3rd and 4th ,5th
gears

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TYPES OF MOTORS

1. Servo based; based on oil , has high efficiency welling

2. Pneumatic based; compressed air based just in case of failure of engine can run on either
of these both

HYDRAULIC SHOP
 Control valve assembly
 Pump assembly
 Pump testing
This test motor, suction pump, discharge pump.

PROCESS TESTS
 Performance test
 Efficiency test
 Noise test
 Oil flow test

MATERIAL SCIENCE LAB

MECHANICAL CHEMICAL METROLOGY
Hardness test Wet method MACRO
Impact test OES MICRO
Tension test C&S By image
Compression test analysis

FATIQUE TESTING
 Ex- H frame
 (100T) dumper
 (50T)- frame
 (EX)-boom

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