TRAINING REPORT

For Six months Industrial Training held in LIGHT MACHINE SHOP AT

VILL CHAKGUJRAN, PO PIPLANWALA JALANDHAR ROAD, HOSHIARPUR PUNJAB.

SUBMITTED TO: Mr. Deep Kanwar H.OD ME Department

SUBMITTED BY VISHAL SINGH 80505114047

Aman Bhalla Institute of Engineering & Technology (Kotli)

INDEX
CONTENTS
1. ACKNOWLEDGEMENT 2. COMPANY PROFILE 3. TRACTOR A BRIEF INTRODUCTION 4. LIGHT MACHINE SHOP 5. TRACTOR ASSEMBLY SHOP 6. DIFFERENTIAL a. ASSEMBLY b. PARTS OF DIFFERENTIAL 7. GEAR BOX a. ASSEMBLY b. PARTS OF GEAR BOX 8. REAR COVER a. ASSEMBLY b. WORKING c. PARTS OF REAR COVER 9. FRONT AXLE a. ASSEMBLY 10. CHASSIS MAIN LOOP ASSEMBLY 11. FINAL ASSEMBLY 12. PROJECT 13. CONCLUSIONS

PAGE NO
3 5

ACKNOWLEDGEMENT

I take this opportunity with much pleasure to thank all the people who helped me through the course of my training. I sincerely thanks to Mr. DEEP KANWAR (HOD), and (training and placement officer) with whose guidance I am able to join Sonalika International Tractors Ltd. Vill.Chack Gujran Distt. Hoshiarpur for six month training.

Apart from during my training I have learnt a lot from other departments colleagues which I am sure will be useful in different stages of my career. I would like to express my gratitude to the other departments such as training center, engine, Plant, HMS, gear shop, R&D and etc. to guide me in every path of my training and provide me best knowledge to understand the product and system.

I would also like to thank my colleague in international department s for their support and useful tips.

I am sure that without the support of above said ITL team, my endeavors had never been result oriented.

SUMMARY

My college provided a six month industrial training program in our complete four year BTechcourse. This training is basically a step to provide an industrial exposure to a student. It is to get first hand technical and practical knowledge about the industry so that when graduate joins the industry they are well versed with various aspects of it.

This training provides an opportunity for better interaction between the undergraduates and the industry employees. I joined my training in the upcoming growing industry INTERNATIONAL TRACTOR LIMITED. I worked along my coordinator as a trainee for six month. While doing my training I went through lots of ups and downs which enhanced my knowledge and personality as per the industrial environment.

I would like to list all the aspects on which my training was based and all the works done by me:--

performance as well.

Learning the process of work flow, how the job is done, all the steps.

COMPANY PROFILE

Established in 1969, Sonalika group from the very beginning has tried to understand customer need so that they get better value for their money, hard earned. Sonalika group is one of the top automobile and agriculture machinery manufacturers in India. Apart from tractors its product line includes multi utility vehicles, three wheelers, engines and various farm equipment and implements. Established in 1969, Sonalika group since the inception has tried to understand customers need to be able to facilitate them with its value for money products. The company has a state of the art manufacturing facilities, spread in acres, located in Punjab and Himachal Pradesh. Today the group stands-tall with an approximate turn-over of 1000 crore. An average growth rate of 30% makes it the fastest growing corporate in India. It also happens to be very few debt free companies in the world. It employs about 2500 people including some of the renowned names in the industry. The company works on the maxims of low production cost and clean and safe environment. Such efforts have fetched the company the accreditations like ISO 9001 and ISO 14001.

The company has a strategic alliance with Yanmar of Japan, earlier it had joint venture with Renault agriculture of France which is now part of Class, Germany. CITI bank and 3I are major financial partners of Sonalika group. Sonalika is also environmentally responsible and has developed in-house engines that confirm to Euro II norms. It is now in the process of developing Euro III compatible engines. Sonalika products have created a niche for themselves not only in India but also in foreign markets including France, Africa, Australia, Bangladesh, Srilanka, Senegal, Malawi, South Africa, Mali, Canada, Syria and many of the south-asian countries

LOGORATIONALE Red symbolizes the, arouses cheerfulness, stimulates mental activity, and generates the same. Green Leaf in the center symbolizes growth, harmony, freshness, and fertility. Black

VISION
The Dream Project of Sonalika group is to cater the agricultural and auto industry with quality abrasive products through untiring dedication and leadership.

MISSION
Sonalika group pays personal attention to their customers so that they get the products which satisfy their needs. CORE VALUES To accomplish our mission, the ownership, staff and management go to great lengths to treat each customer like a member of the family and provide them with the best choice of products and highest quality of service in the industry.

TRACTOR - A BRIEF INTRODUCTION

History of Tractor:In the year 1856, all such machines used for traction purposes were known as traction motors and later in 1906 , these were designated as tractor by taking half the word from traction , i.e. trac and the other half from motor , i.e. tor. Definition of Tractor:The tractor is such a machine which is used to pull or push agricultural implements in the fields..

A wheeled, self-propelled vehicle for hauling other vehicles or equipment and for operating the towed implements; also, a crawler, which runs on an endless, self-laid track and performs similar functions. A farm tractor is a multipurpose power unit. It has a drawbar for drawing tillage tools and a power takeoff device for driving implements or operating a belt pulley. The acreage to be worked, type of crops grown, and the terrain all impose their requirements on tractor design. Accordingly, models vary in such details as power generated, weight, ground clearance, turning radius, and facilities for operating equipment. All models can, however, be grouped under four general types: four-wheel, row-crop or high-wheel, tricycle, and crawler. Tractors are rated by their horsepower they deliver at the drawbar and at the belt. On small models, the drawbar and belt horsepower may run as low as 10 (7.5 kW); on large models the drawbar horsepower runs as high as 132 (98 kW), while belt horsepower reaches about 144 (107 kW). The major components are engine, clutch, and transmission. These components are intimately related and designed to work in conjunction with each other to accomplish specific work. Tractor engines are relatively low-speed; their maximum horsepower is generated at crankshaft speeds in the neighborhood of 2000 rpm. These engines have one, two, three, four, six, or eight cylinders and operate on gasoline, kerosene, liquid petroleum gas, or diesel fuel. They are of the spark-ignition or diesel type, operating on

the four-stroke-cycle principle, and are cooled by water or air. Power is transmitted to the rear wheels or to all four wheels.

Main Assemblies of Tractor :Engine :Engine is a set of mechanical devices which convert chemical energy into heat energy and heat energy into mechanical energy. Engine provides the source of power to drive the tractor .Sonalika engines are Compression ignition , Water cooled ,Four stroke, Diesel engines. Clutch :Clutch is fitted between the engine and gearbox and is used to connect or disconnect the engine drive to the geaabox. Transmission :Gearbox is fitted in the tractor to increase the driving torque so as to enable the tractor to pull more load. In the gearbox housing ,differential and reduction gears are also fitted. The differential helps to take a turn without its inner wheel spinning while the reduction gear fitted further increases the driving torque to the wheel. Wheels :Two wheels are fitted to the front axle and two rear wheels to the reduction gear shaft , drive is transmitted through the rear wheels . For better traction in tractors , rear tyres are provided with high lugs. Front Axle :Front axle is fitted at the front of the tractor and the two stub axles fitted at either end through which the steering linkage is connected and wheels are steered. Steering System :Steering system enables the operator to steer the tractor to right or left as the case may be.The steering unit in power steering tractor is hydrostatic i.e. there is no mechanical connection between steering column and steered wheels .Instead there are hydraulic pipes and hoses between steering unit and steering cylinders.When the steering wheel is turned , the steering unit meters an oil volume propotional to the rate of rotation of steering

wheel.This volume is directed to the appropriate side to the steering cylinder, while simultaneously the displaced oil is directed to tank. Brake System :Brake system provided in the tractor so as to enable the operator to stop the moving tractor or slow down the speed when required. Electrical System :Electrical system provided in the tractor enables it to work in the night through the electricity produced by dynamo. Moreover , engine is also started through self starter which draws its electric current through batteries. Hydraulic Lift :With the help of hydraulic power the implements are raised or lowered Down or their depth is controlled. Power Take Off :Provision is made in the tractor to drive stationary or moving implements such as Sprayer, Duster, etc.

10

LIGHT MACHINE SHOP

INTRODUCTION: L.M.S. is shop for manufacturing small components of the tractor in Sonalika. International tractors limited. This is a small shop where light components operations are performed on the light components of tractors. There are about different types of machines where different operations are performed on different components for production work. Main operations performed in L.M.S. are as follows: DRIILING TAPPING REAMING MILLING Etc. Components made in L.M.S. shop are as follows: 1. Response valve housing 3. Release valve 5. Gear shifter lever 2. Relief valve 4. Piston for relief & release valve 6. High Low leaver FACING TURNING BORING GRINDING

11

MACHINES IN L.M.S R.V.HOUSING LINE: Following are the machine used in R.V.housing: 1. Center lathe-I 3. Boring machine 5. External drilling machine 7. Center lathe II 9. Radial drilling machine-III 11. Tapping machine 13. Washing machine 1. CENTER LATHE: Facing is done in this machine. This is the machine on which first operation is done response valve housing. On this machine job is rotated and the cutting tool is moved related to job and facing is done on the one side of the R.V.Housin 2. RADIAL DRILL MACHINE-I: In this machine four hole of dia 13mm, 12.8mm, 13mm & 12.5mm is drill on the R.V. housing for mounting with the rear cover. 3. 2. Radial drilling machine-I 4. Radial drilling machine-II 6. Milling machine 8. Turret lathe 10. Radial drilling machine IV 12. Surface grinder

BORING MACHINE: -

This machine is used for boring the center hole of dia 28mm & chamfered of dia 25mm. This hole used for mounting the response valve. 4. RADIAL DRILL MACHINE-II: -

12

THE machine is used for drill the two hole of dia 9mm and at a depth of 25mm which is match with control valve hole and one hole of dia 9mm and depth 10mm witch is match with ram cylinder hole. 5. EXTERNAL DRILL MACHINE: This machine is used for drill the hole of dia 9mm and hole is passed from response valve through which oil is come back from ram cylinder through response valve to control valve hole. In this machine dia of 16.5mm hole is also drill for fixing the plug to prevent the oil leakage through this hole. 6. MILLING MACHINE: In this machine milling operation is done on all the side face of the R.V.Housing. 7. CENTER LATHE-II: In this machine a rough hole of dia 9mm is drill which is linked with the ram cylinder hole and the end of this hole we drill the hole of dia 20mm for fix the plug to prevent the oil leakage from this hole. 8. TURRET LATHE: In this machine the hole that is roughly drill in radial drilling machines & center latheII & is drill smoothly and give the final shape. In this machine the chamfering and tapping operation is also done. 9. RADIAL DRILL MACHINE-III: In this machine hole is drill for mounting the relief valve. 10. RADIAL DRILL MACHINE-IV: In this the hole of dia 5mm is drill & then chamfering of dim 0.5 45 is done. 11. TAPPING MACHINE: -

13

This machine is used for tapping operation is done on the response valve hole, relief valve hole, ram cylinder hole & control valve hole. 12. SURFACE GRINDING MACHINE: This machine is used for grind the hole that is not finished and gives the final shape to the R.V.Housing. 13. WASHING MACHINE: After all the operation is done R.V.Housing is washed properly. RELIEF & RELEASE VALVE HOUSING LINE: Following machine is used in relief & release valve housing: 1. Turret lathe 3. Testing machine 2. Honing & lapping machine

1.

TURRET LATHE: In this machine drilling, milling, reaming & chamfering operation is done. In this machine first drill the hole of dia 11mm, then mill the hole of dia 11.8mm, then ream up to dia 12mm, then chamfering is done of dim 0.5 45.

2.

HONING & LAPPING MACHINE: In this machine the valve, which is drilled, milled, reamed &chamfered on turret machine, is than honed on the honing machine and than lapped on the lapping machine. The honing is done for setting the ball on the chamfered to make the exact pressure in the valve.

3.

TESTING MACHINE

14

In testing machine the release valve and relief valve pressure is tested. The testing operation is as follows: 1. 2. 3. Insert taper washer in valve screw in assembly in pressure test equipment. Pump hydraulic oil till it reach release or relief valve. Screw to as out to set cracking pressure (c.p.) at 175 kgf/cm for relief valve and

195kgf/cm for release valve. 4. Check holding pressure up to 170 kgf/cm for relief valve and 190 kgf/cm. 5. Check the cracking and holding pressure for 5-times and then remove the assembly

from the testing machine.

GEAR & HIGH LOW SHIFTER LEVER LINE: Following are the machine used in gear and high low shifter lever housing: 1. Copy turning lathe 3. Copy lathe 5. Radial drilling machine 6. Bench threading machine 2. Surface plate 4. Milling machine 5. Grinding machine

1.

COPY TURNING LATHE: In this machine turning operation is done with the help of masterpiece. Master piece witch is all ready turned according to the dimension is fixed with the help of fixture and job is fixed in 3-jaw chuck. In this machine the facing of ends of blankets up to 110mm deep is done, drilling of size 5mm is done and at last turning is done.

2.

SURFACE PLATE: -

15

After facing the height of the leaver is checked on the surface plate with the help of height gauge.

3.

COPY LATHE: After checking the height the facing, turning and grooving of dia 13.5mm is done in this machine.

4.

MILLING MACHINE: In this machine the multiple operations are done. In this machine first the key way is cut of R-31.5, then rear side is face and then bob is made of dia 12mm.

5.

RADIAL DRILLING MACHINE; In this machine the hole of dia 4mm is drilled on center of the sphere at a distance 16.7 from rear end.

6.

GRINDING MACHINE: In this machine grind the lever up to accurate dimension.

7.

BENCH THREADING: After grinding the external threading is done finally on the planeside of liver of size 12 1.75mm.

HEAT TREATMENT: Heat treatment is the operations of heating and cooling of metal in its solid state to change physical properties. According to the procedure used steel can be hardened to resist cutting action and abrasion, or it can be softened to permit machining with proper

16

heat treatment. Internal stresses may be removed, grain size reduced, toughness increased or a hard surface produced on the hard ductile interior.

In the heat treatment section the various processes like carburizing, quenching, tempering, normalizing, annealing and washing of the different components are done. Normalizing and annealing is done on the forgings before machining. The main objective in H.T. shop is case hardening which is done for gears, shafts and other sheet metal materials. The purpose of Case hardening is to form unlike carbon rich steels which can be hardened by heating, mild steels do not contain enough carbon to perform this operation. Instead carbon is forced into the skin of the metal to produce a piece of mild steel which has an outer casing containing more carbon than its core. This process is known as case hardening. The operation is simple. The mild steel is heated to a bright red and whilst it is softer it is dipped into a carbon compound which soaks into the outer surface. One dipping is not enough and re-heating and dipping should be done several times. This will produce a carbon rich skin or case of about 1mm thick.

17

Once the casing has been produced the metal is heated to a bright red and this time dipped in water to harden it.

Case hardening can be useful for making pieces which need to be hard on the outside to resist wear and tear, but softer on the inside to resist shock or sudden blows. The sequence of operations done on a particular component is As follows:(i) (ii) (iii) (iv) (v) (vi) (vii) Punching on the components. Fixture preparation. Washing of components. Carburizing. Quenching. Washing of the components. Tempering.

(viii) Shot blasting.

LIST OF COMPONENTS GIVEN HEAT TREATMENT ARE:1. Gear z-28. 2. Intermediate shaft 3. Dog gear z-36 18

4. Dog gear z-32 5. Dog gear z-32 6. Input gear z-50,52,53 7. PTO gear z-37 8. Gear z-29 9. Gear z-28,25 loader special 10. Idler rev gear z-24 11. Drive shaft z-18 12. PTO rear shaft 13. HOB(for intermediate shaft) 14. PTO gear z-33 15. Gear PTO z-56 16. Bull gear 17. PTO slide 18. PTO internal gear 19. PTO slide. 20. Gear z-35. 21. Bull pinion shaft. 22. Input shaft without gear. 23. Input shaft gear z-21, 23, and 24. 24. Hi/low intermediate shaft. 25. Sleeve small. 26. Sleeve big. 27. Internal gear. 28. Sleeve-37 29. Bp shaft. 30. Bull gear. 31. Input shaft. 32. Lever. 33. Sleeve-68 34. Output shaft. 35. Idler cluster. 36. Ring gear. 37. Drive shaft. 19

38. PTO fix. 39. Sleeve52/16. 40. Lay shaft. 41. Process for normalizing (8620). 42. Process for normalizing (EN28/EN9). 43. Process for stress relieving. 44. Bush spool valve. 45. CM gear z-43, 46.

In the heat treatment plant there are various furnaces and tanks used for different purpose. Carburizing is carried out in gas carousing furnace (GCF).The process of tempering is carried out in tempering furnace. Quenching and washing are carried out in quenching tank (QT) and washing tank respectively. Beside of these furnaces there is a shot blasting machine which is used for cleaning of the components .In this machine the components are held in the fixtures and then small size metal balls strikes there surface to clean there surface.

STEPS IN WHICH THE COMPONENTS OPERATED IN THE HEAT TREATMENT PLANT ARE:-

(1). PUNCHING OF THE COMPONENTS:Machine name: - punching machine. Operation: - Punching. Tool used: - Number punch. About operation:-

20

All the components are given codes or numbers first. The punching machine is hydraulically operated. The jobs are held in the fixture and then with help of a punch different codes are punched on the jobs.

(2). FIXTURE PREPARATION:After punching fixture preparations is done. In this operation the fixture prepared according to the size, shape and quantity of the components. The fixtures are very large in size and can carry numbers of gears, shafts and other small components.

(3).WASHING OF THE COMPONENTS:This is done in the washing tank to remove the oil from the component which is on them because of machining. For washing of the component water and caustic soda is used. Caustic soda is used because oil can not be removed by water alone caustic soda is useful in removal of oil from the surface of the components. In washing tank there are number of nozzles through which water and caustic soda mixture stakes over the surface of the component at high pressure, this high pressure

helps in removal of oil and other impurities.

(4). CARBURISING:This is the phenomenon by which carbon penetrate the steel. Iron at temperature above its critical temperature has affinity for carbon. The carbon is absorbed into the metal to convert outer surface into high carbon steel. The depth of case depends upon the time and temperature of treatment. The atomic size of iron (Fe) is less than that of atomic size of carbon (c) so, the Penetration of carbon cannot be done easily, that is why heating of metal is done. The metals heated above critical temperature, at this state the atomic size of iron increases and 21

hence penetration of carbon can be done easily. The iron and carbon after cooling forms an intermediate atomic size. The carburizing is done in gas carburizing furnace (GCF). The temperature inside

The furnace is set according to the requirement. In GCF there is a drip feed panel through which the quantity of isopropanol is controlled. In carburizing isoprpanolis used for making carbon at high potential. The percentage of isopropanol is controlled with the help of drip feed panel. When the liquid from the drip feed panel enters the furnace it atones burst into a gas having carbon at very high potential. Since carbon has property to flow from high potential towards the low potential therefore it is helpful for the penetration of carbon into steel. When the temperature inside the furnace reaches about 930 c, the penetration of carbon in the steel started. This penetration of carbon into steel at temperature 930 c is called active carburizing. After active carburizing the drip feed amount stops i.e. there is no drip feed given but the temperature remains the same, now the penetration of carbon gradually decreases and also the percentage of carbon decreases this is called diffusion carburizing.

22

The active and diffusion carburizing are done alternatively because if they are not done alternatively the percentage of carbon in the component suddenly increases which will damage the grain structure of the components and also some extra carbon get attached to the surface of the job and its removal is very difficult. After active carburizing and diffusion carburizing reduction carburizing is done. In reduction carburizing the drip feed amount decreases and the temperature inside the furnace decreases from 930-810 c. If the temperature and the drip feed does not decreases this will effect the grain size and shape of the job, therefore when the temp. Decrease the job acquires its original grain size. Heat treatment is the operation of heating and cooling a metal in its solid state to change its physical properties.Acc. To the procedure used, steel can be hardened to resist cutting action and abrasion, or it can be removed grain size reduced, toughness increased, or a hard surface produced on an educible interior. QUENCHING:-

Quenching or rapid cooling from above the critical temp. By immersion in cold water or other cooling medium, is a hardening treatment. It increases the strength of the metal and increases the wear resistance, but makes the metal brittle and of low ductility.

23

Testing parameters and indicative limits for quenching oil are:-

S.NO.

PARAMETE RS TESTED

TEST EQUIPME NT

TEST METHOD

SPECIAL LIMITS FOR OIL FRESH

INDICATION LIMITS FOR OIL USED

1.

Kinematics viscosity at 40 c

Viscometer temperatur e controlled both soap and water

ASIMD 445

20-25

19.32

2.

Specific gravity @30 c

Hydromete r 500ml cylinder

ASIMD 1298

0.84-0.87

0.83 minimum

Flash point

Flash point

ASIMD

178 C

178 C

24

3.

apparatus

92

4.

Specific value of mgkOH gm

All condenser

ASIMD 94

Less than 1.0

5.

Acidic value

Karl fisher titrate

ASIMD 1744

0.2 maximum

6.

Water constant

Centrifuge apparatus _

Less than 1.0

25

7.

sludge

Centrifuge apparatus

ASIMD 91

Less than 1.0

(6). WASHING:After quenching the washing of the component is done. The washing us done to remove oil dust and small chips from the surface of the components. The mixture of water and caustic soda is used for washing. It is carried out in the washing tank where number of nozzles throws the mixture of water and caustic soda at a very high pressure on the surface of components.

(7). TEMPERING:Tempering consist of reheating below the critical temperature. The quenched metal to restore some of the ductility and to reduce the brittleness. Increased toughness is obtained at the expense of high strength. The table representing the tempering of an intermediate shaft is shown below:-

26

S.NO

PROCESS

DETAIL OF PROCESS

TEMP.

D.F.A

1.

Loading

Loading of charge in GCF at 920-930 c

920-930 c

Nil

2.

Heating cycle

After loading temp. Fall to At temp. At temp At temp.

600-650 c

Nil

750-770 c 850-870 c 910-930 c

0.1-0.4 LPH 0.8-1.0 LPH

3.

Carburizing

Carburizing temp. Carburizing contd. Upton C.P goes to 0.81.0% Checked by carbon Apparatus or by oxy Probe. cycle

910-930 c

LPH 1.0-1.2LPH 0.4-1.2 LPH

4.

Diffusion

(a) feed to stop when

910-930 c

LPH

27

0.8-1.0%C.P received (b)when C.Preduced to 0.6-0.7%(C.P to be checked by carbon determination or by oxi probe) (c ) repeat (a) &(b) until case depth 0.6-0.7 mm achieved Nil 0.4-1.2 LPH method 910-930

5.

(note)

Take out at least two Pin on regular interval Of time from the start Of different cycle for Checking of case depth Until depth is achieved.

6.

Cooling cycle

Switch of GCF2 shut Down temperature (a) ensure oil temperature between 60-80 c (b)quenching the charge Q.T ensure the C.P of 910-930 c to 800-830 c

28

GCF 0.7-0.9% at the time of Quenching.

7.

Tempering

Temper the charge at 180-220 c in tempering Furnace the I-5hrs. (tempering time is depending upon surface hardness achieved after and thickness Of the component).

180-220 c

0.2-0.4 LPH

SHOT BLASTING:Machine name: - shot blasting machine Operation:-cleaning of carbon from the surface of components Shots material: - High carbon steel balls. Speed of shots:-80m/sec.

In this machine the different components are placed on the two big size plates which are attached to the two big gates. At one time one gate is kept closed and one is kept open. When one gate is closed the machine gets started and then the high carbon steel balls strikes at a speed of 80m/sec on the surface of the components to clean carbon stick to their surface. Shot blasting is done in a machine called shot blast. In the 29

process of carburizing some extra carbon get attached to the surface of the components which can easily remove with the help of shot blasting. For the removal of carbon from the surface of gears it takes 2-3hrs of operation in shot blasting machine. When the process starts the table starts rotating and the shots from the top of the container falls on the components. The shots come down with the help of the motor of 20HP. For cleaning of carbon different size Of shots are used.

The process is carried out in 12min for bull gears, 19min for small gears. This time variation is given according to the hardness of the gear or shaft e.g. if the hardness of the simple gear is from 30-35 we will give 3-4 min for its shot blasting. If the hardness varies from 60-70 we will give 10-20 min for its shot blasting no matter what is the size of gear.

BENCH CENTRE:This machine is used to check the diameter ands PCD of the shafts. In this machine the shaft is fixed between the two rotating ends, now the dial

30

gauge is used to take the readings. The anvil of dial gauge is allowed to touch the surface of the shaft, after that the reading of dial gauge is made to some constant value. Now the shaft is rotated manually. The standard reading of dia is 0.1mm and where as PCD is 0.05mm is checked. If the reading comes same the shaft is ready but if it is not coming out to be more at perpendicular point that point is pressed with the help of hydraulic press and then reading is checked on dial gauge. If reading is coming according to the standards then opposite side of the shaft is pressed to required size.

(10). DEBURRING MACHINE:Operation: - Debarring Tool used: - Grinding wheel

OPERATION DESCRIPTION:(1) The operation debarring contains grinding of the gear teeth edges. AT the edges carbon is collected the edges become brittle which may cause breakage at edges the gear teeth. (2) The job is held by the help of chuck of the table. (3) There are two grinding spindles. Heights of both there spindles can be set down according to the size of the job. (4) The movement of the spindle is operated by the air pressure. Setting of the movement of the spindle is manually operated according to the no. of teeth and module.

Following are the main shafts and gears on which teeth and splines are cut in gear shop of Sonalika international tractor ltd. 1) B.P left shaft 2) B.P right shaft 3) Input shaft 4) Intermediate shaft 5) Lay out shaft

31

6) Output shaft 7) Gear z-18 8) Gear z-23 9) Gear z-25 10) Gear z-26 11) Gear z-32 12) Gear z-33 13) Gear z-34 14) Gear z-35 15) Gear z-36 16) Gear z-37 17) Gear z-39 18) Gear z-35 (sliding) 19) C.M gear z-47 20) C.M gear z-43 (duel) 21) C.M gear z-45 22) Ideal clutch gear 23) Coupling sleeve 24) Sleeve

MACHINE USED:a) Turning phase b) Hobbing, shaping and shaving phase c) Grinding and inspection phase 32

a) TURNING PHASE:In turning phase of gear shop rough and finishing of components is done. The components from the casting is machined to a form usable in hobbers and shapers. The main function of turning shop is to control the outer diameter, F.O.D, F.T, dimensions, internal diameter and bar diameter.

Following are the main machine used in turning phase 1. Centering and facing machine. 2. Six centre lathe. 3. Two S-pilot machines. 4. Radial drilling machine 5. Two T-piloteor chuck machines. 6. Broach machine.

1. CENTERING & FACING M/C:It is the machine where centering and machining is done first of all to start the other work on it. Job is holding on special type of fixture. The facing is done on components with the help of inserted blade shell end mill cutters. The total dimensions of shafts is also controlled by the same operation. After facing the centering is done on the components with the help of drill. The center axis of same machine must be aligned in the same axis, as this axis act as reference to other operations on components.

2.CENTRE LATHE:-

33

In turning phase of gear shop six center lathe is used. On this lathe different operation are done to control outer dia , flange thickness(f t), flange outer dia(f o t), bar outer dia, internal dia and other dimensions. Firstly rough turning is done on the components. It is used where excessive stock is to be removed and surface finish is not critical. For such operations deep cuts with the coarse feed are used. for rough turning the cutting edge of tool is located about 0.4 mm above work center for each 0.6mm dia. cooling of tool is done time to time to save the tool from burning. During rough turning maximum material is removed and very little extra material is left to make final cut. micro meter , snap gauges etc are used for final dimensions.

3.

S-PILOT:Two s-pilot machines are used in gear shop. The

meaning of s-pilot machine is that the tool used (tungsten carbide) is perpendicular to job as compared to other machines. So it is called as straight pilot machines. It is also called copy turning machines which is hydraulically operated. The components or job are hold in hydraulic chuck. The main function of this machine is to do copy from the master piece with the help of follower or tracer. This machine is simply a lathe machine with a special attachment which is known as copy attachment. Rough finished components are used on this machine for final dimensions.

4.

CHUCKMATIC LATHE:Two chuckmatic machines are also used in gear shop. This

machine is also called as t-pilot machine. In this type of machine tool is inclined to the job so this machine is called as Trans pilot machine. This machine is less rigid than the s-pilot machine but more used because of quality of finishing is superior the machine is hydraulically operated and used for finishing gears, sleeves and other parts. The job is hold in the chuck and through inserts are used for finishing the components. For controlling the dimensions micro meter ,snap gauges and vernier calliper are used. 34

5.

BROACH MACHINE:Broach machine is used to cut the internal splines on sleeves,

gears and other parts. Pull type broacher is used to cut the splines. The single pass of broach cut away the internal splines. Broach machine decrease the cost per piece and

increase the production. The machine is hydraulically operated. Different sets of internal splines are cut with the different broach tools.

b)

HOBBING & SHAPING AND SHAVING PHASE In hobbing phase of gear shop the outer teeth are cut

with the help of hob cutter. In shaping process the internal gears are formed on job. After the gear formation the shaving is done on gears for finishing and accuracy. Following are the machine used in shaping, hobbing and shaving. 1) Four hobbing machine 2) Two shaper machine.

3) Four shaving machine. 4) Two gear tooth-rounding machine.

1. HOBBING MACHINE. :Four hobbing machines are used in gear shop. On different hobbing machines

different components (left B.P,right B.P,gears ) are made. Hobbing is the process of generating a gear by means of relative cutter called as hob. It is a continue indexing process in which both the cutting tool and work piece rotate at a constant relationship while the hob is constantly feed on to job. A hob resembles a worm with gashes made parallel to its axis to provide cutting edge. For involutes gears the hob teeth are relieved radically to form clearance behind the cutting edge the 35

hob is feed into the gear plank to the proper

depth and the two are rotated

together as if in mesh. The teeth of hob cut into the work piece in successive order and each time in a slightly different position. Each hob tooth cut its own profile depending on the shape of cutter (which in case of involutes gears is of straight sided) but the circulation of these straight cuts produces a curved form of the gear teeth ,thus the name generating process. One rotation of the work

completes the cutting up to certain depth which is according to the feed given to the hob. The gears cutting with hob involves three basic motion which are occurring at the same time. The hob and the plank have rotator motion and at the same time the hob is having radial motion which causes the cutting and indexing simultaneously. The hob cutter is set with its teeth parallel to the axis of gears blank when spur teeth are to be cut , the axis of the hob can be set at an angle to produce proper helix. The hob axis is set out at an angle to produce the proper helix. The hob axis is set out at an angle. This brings the blank teeth in the plane of the hobs teeth. This plane is termed as gear as generating plane. The cutter finish all the teeth in one pass over the work. Selection of proper gear ratio

enable the hob to rotate in correct relation to the gear blank , so as to cut the specified numbers of teeth several gears are to made at one loading of the

machine the hob is caused to move along the blank after revolution of the work. Work table and hob have to rotate in definite

relationship obtained by index change

gears. For hobbing

helical gears the

rotation of work table in slightly advanced or retarded in relation to the rotation of the axial feed screw by means of another set of change gears called as by the

differential change gears. The differential change gears are calculated following relationship

between the axial feed screw and the work table rotation.

(Revolution of axial feed screw) (lead of axial lead screw) = (additional revolution of work table ) (lead of work piece held) An accurate relationship is required between various elements of machine in order to achieve the required result. Worktable and hob has to

36

rotate in definite relation formula is

obtained by indexing change gears. Index change

gear

(No. Of teeth on driving index change gear / No. Of teeth of driven index change gears) = (Indexing constant No. Of teeth on hob / No. Of teeth to the cut.) Special features for hobbing machine Heavy box type bed closed frame construction. Shortest path fir power transmission from motor to hob. Max diameter of spur or worm gear.(500 mm) Max module (8 mm). Max travel of hob slide=300mm. Hob dia /length =186/170mm. Work table dia =400mm. Main motor (9 kw). Hydraulic motor =1.5kw.

2.

GEARS SHAPING MACHINE:-

There are two gear shaping machines in Sonalika International Tractor Ltd. One is used for internal spur gear formation and other is used to form external spur gears on blank.

37

The

main

difference

between

shaping

and

hobbing

machine is that that the rotary cutter is vertical provided in both shaper machines. The work pieces is rotating on its own axis and cutter is also rotating on its own axis with up and only. The cuter is hardened disc shaped and slightly dished at the bottom (ground with top rake and clearance) to facilities cutting. The teeth have desired tooth profile and pressure angle. The cutter is reciprocated with the required cutting speed for stock removal along the face of the work piece and is gradually feed radically to plunge in for correct teeth depth by means of cam. The relieving mechanism enables the cutter to clear the work on non cutting or return stroke. The continuous generation motion is obtained by feeding cutter to true depth and rotating the cutter and work piece slowly of their in exact ratio down vertical movement. This machine cut the spur gears

respective no. of teeth by means of chain of gears. The cutter is

considered as the driving gear and the work piece as driven gear. The work piece gear is fully generated when the cutter has plunged to correct tooth depth into the work piece and the tooth are cut fully and uniform ally over the entire prepay of the work piece. The machine comes to rest gear is fully cut. automatically after the work piece

3.

GEAR SHAVING: -

38

It is the latest method of gear finishing. It is cold working process accomplished by rolling the gear in contact and pressure with the cutter. The teeth of cutter are serrated normal to the tooth profile and in operation , the cutter and the work piece are meshed together as helical gear with the planes of their respective axes crossing. In process the one member is driver and the other member is follower the new parallelism of axis causes sliding action between the teethes. Shaving improves the gear the finishing which is not possible in cutting process. With high speed hobbers we always get small error in the pitch ,profile and concentricity. This process is idle for automotive gear box and is done after hobbing and before hardening. The disadvantage of this process is that the surface of tooth is covered with amorphous or smear metal rather than metal hobbing true crystalline structure.

C)

GRINDING AND INSPECTION:-

39

There

are five internal and external girders in use. Heat

treated shafts are grinded to provide the finishing and proper size in microns to match with the bearing size. Grinding is done on the B.P left, B.P right ,P.T.O shaft and other work for setting properly with the bearings. With the help grinding the size of components is controlled in microns. External and internal grinding is done on the shafts and gears. Very small amount of material is removed about .02 mm from job. During grinding the cooling of components is done to avoid overheating. After grinding the inspection is done on the components to check the accurate size. The testing of gears is done to check the concentricity , spacing , size , noise level , tooth bearing , pitch , module ,gear profile etc. All test are made with accurate, calibrated, rigid and in shortest time. instruments and machine used in gear shop Following are the main

40

S.NO.
1) 2) 3) 4) 5) 6) 7)

INSTRUEMENT
Vernier caliper Vernier caliper Vernier caliper Vernier caliper Depth vernier Depth vernier Micrometer

SIZE
0-100 0-200 0-300 0-600 0-200 0-300 0-25 25-50 50-75 75-100

8) 9) 10) 11) 12) 13) 14) 15)

Flange micrometer Puppy dial Plunger dial Bore gauge Magnetic dial stand Thread gauge Shape gauge Pneumatic bore gauge

0-25, 25-50, 75-100 10 micron 10 micron 18-35

41

Quality Of Products:It is Systematic control of those variables encountered in a manufacturing process, which affect the excellence of the product. Such variable result from the Application of material, men, machine and manufacture-ring conditions only when these variables are regulated to the extent that they do not detract unit is main shop of sonalika international tractor ltd .In necessarily from the excellent of the ring-ring process as reflected in the quality of the finished product, can the control of quality be said to exist. Generally, inspection, which is the process of sorting good from bad, is the process of sorting good from bad, is considered as a form of quality control. But quality control and inspect-ion are different. Conceptually, a Q.C. aim of prevention of defects at the very source relies on effective held back system and corrective action procedure. Acceptance of material after subjecting them to in section at inward goods store is inspection concept. Q.C.concept is to take early step to ensure that the material to be supplied is going to be manufactured to the plant's requirements. So as to ultimately eliminate the in ward goods inspection. Discovering that the components produced are not as per required dimensional specifications due to wrong tool or improper settling after the production is over is inspection concept. To prevent the issue of a wrong tool and to have a set up approval procedure prior to starting continuous production and keeping a simple check during production, are Q.C. concepts. Q.C.uses inspection as a valuable tool. In quality control programmed inspection data are effectively used to take prompt corrective actions to arrest the incidence of defects in the job on hand to plan the prevention of occurrence of the same or similar defects in future.

42

OBJECTIVE:The main objective of a quality control programmed in sonalika international LTD. (1) Evaluation of quality standards of incoming material, product in actual

manufacture, and have out going product. (2) Judging the complicity of the process to the established standard and taking

suitable action when deviations are noted. (3) (4) (5) (6) Evaluation of optimum quality obtainable under given conditions. To improve quality and productivity by process control and experimentation. Developing procedures for good vender vendee relations. Developing quality consciousness both within and outside the organization

QUALITY CHARACTERISTICS
Following are main quality characteristics for components used in sonalika international tractor ltd. (1) (2) (3) A dimension is a characteristic. A chemical properties is a characteristic. A sensory properties is a characteristic.

All these characteristics contribute towards the quality of the product. So we can say that appearance of product is a quality characteristic ices of the product. Similarly performance, length of life, dependability, reliability, durability, maintainability, fed, sound etc. are all characteristics is like a building block that goes in to the construction

of say, an arch, which may be considered to be quality

43

FACTS OF QUALITY The quality characteristics can be grouped in to following categories in sonalika I.T.L. (1) (2) (3) (4) Quality of design. Quality of conformance. Availability. Customer service.

(1) QUALITY OF DESIGN: The design must meet all the requirements of the customer. The designer has to take into account the question of appearance, reliability, maintainability of the products. The designer should aim at a design, which fulfills all the qualities or almost all qualities desired by the customers. He should also aim to make a product, which would become competitive. The designer should be fully aware as to what requirements of the customer are, what characteristics are to be make the products acceptable to the customer, what are the service condition, etc. He should be able to translate all these into clear specification and drawings. There should be no ambiguity in information.

(2) QUALITY OF CONFORMANCE: The degree or extent to which a product actually conforms to in accordance with the specification and drawing is called the quality of conference.

44

(3) AVAILABILITY: This includes such characteristics as reliability,

maintainability and length of life. All these indicate as to what extent the product will be available for use. Reliability of a product may be taken as the extent to which it can give continuous service. If a product breaks down frequently it is not reliable, as customer are not getting its service continuously as they want. If product is such that to take off an extent assembly, they have to dismantle the whole machine them this is not an easily maintainable product.

4) CUSTOMER SERVICE: This indicates the extent to which the customer can get assistance from the manufacture or to keep the product in continuous use. This service is an after sale function. Replacement of defective components, conveying sufficient technical know how to customer for maintenance through maintenance manuals, leaflets etc deputing experts to customers place for commissioning and attending to breakdowns, training the customers staff for proper maintenance of the product, etc. are some of the services given by the manufactures.

QUALITY AUDITING
Quality audits are performed to find whether the end product satieties the desired quality specifications proper functioning of all equipment and machinery operators is carrying out their duties as per specified quality plans. Special care must be given for auditing of tools and gauges, testing quality plans, specification and drawings. Audits should be carried by unbiased persons and without prior announcements and cover each and every persons. Checklists should make audits and its results recorded and made available to all concerned people. The aims of audit should not be penalize but to take measures to correct the deficiencies should during the audits.

45

Following are main instruments and machines, which are used in quality control shop. All these instruments as per their components drawing sizes. (1) (3) (5) (7) (9) (11) (13) (15) Veriner calipers (Of diff. sizes) Plug gauges. Flange micrometers. Hardness tester M/C. veriner depth gauges. Flange dial indicator. Surface plates. Spline ring gauges. (a) Ordinary type. (b) Magnetic type. (17) (19) (21) (23) (25) (27) Bench centering M/C. Slip gauges. Magnetic dial stand. Angle plate. Master cylinder. Veriner caliper for grove checking. (18) (20) (22) (24) (26) Parkinson gear tester M/C. Filler gauges. Manual jack set. Thread plug gauge. Inside micrometer. (2) (4) (6) (8) (10) (12) (14) (16) Snap gauges. Pneumatic bore gauges. Micrometers. Veriner height gauges. Bore gauges. Puppy dial gauges. Veriner bevel protractor. V-block

In quality control shop of I.T.L. which containing further diff. phase for quality checking of different components. 46

(1) (3) (4) (6)

Gear and shafts phase of Q.C. Fabrication and sheet metal phase.

(2) (4)

Casting phase. Alloy steel and forging phase.

Hard wear bought out, electrical and engine phase. Standard room.

GEARS AND SHAFTS PHASE OF Q.C.: In this phase of Q.C. the gears, splines and shafts are checked as per their drawing requirement. Those gear and shafts, which purchased out side and made in there on gear shop are checked as per their drawing dimension. Different tests are done performed to check the gears and shafts.

ROLLING TESTING: This is most commons used test under production condition. This consumes much less time and gives quite accurate results. In this testing the gear to be tested is actually com-pares with hardened gear and ground master gear. This test reveals any error in tooth form, pith and concentricity of pith line. When two gears are in mesh with each other, then any of the above errors will cause the variation of center distance. This fact is utilized for testing the error in gear by testing m/c.

HARDNESS TESTING: Harshness of gear tooth should to ensure that heat treatment is proper and that the desired hardness (as per their drawing specification (required) due to provision of adequate thickness and grain size have been attained. The brinell hardness testing and Rockwell testing m/c is used to test the hard-ness of gears and shafts.

47

RUN OUT TESTING: Run out means the eccentricity in the reference or pitch circle Gears that are eccentric tend to have a vibration per revolution. The run out in the gears is measured by employing gear eccentricity testers. The gear is held on a mandrel in the centers and the dial indicator of the tester possesses the special tip depending upon the module of gear checked. The tip is inserted b/w the tooth spaces. The gear is rotated tooth by tooth. The max. Variation is noted from the dial indicator reading and it gives the run out of the gear. The run out is twice the eccentricity.

BACKLASH MEASUREMENT: Backlash in gear is play b/w the mating tooth surfaces. Backlash in the gear teeth results on account of errors in profile, pitch thickness of teeth etc. It is measuring by mounting gearing specified position Backlash measured at the tightest point of the mesh. The pinion is held solidly against rotating and a rigidity mounted dial indicator is placed against the tooth at the extreme heel perpendicular. It is determined by moving the gear back and forth. It is measured by locating the point of max. And min. backlash in the pair and obtaining the difference.

BORE GAUGE: Bore gauge is used to check the bore of gears and shafts. Along with the measuring probe setting rings are also provided to zero set the indicator. Actual ring size is engraved on the ring frame to the closest 0.001mm value.

VERNIER HEIGHT GUAGE: Vernier height gauge is mainly used to check the length and the height of shafts. The puppy dial indicator is clamped with height gauge. It exactly gives the indication when dial tip is touching the surface. Outer dia is measured with help of micrometer of different sizes. The T.T.C.E. (tooth to tooth composite error), P.C.D., M.O.T., T.T.E. (tooth thickness error) and etc are also checked as per their drawing specification.

Main components are checked in the gear phase are: B.P. left and right shafts. Bull gears.

48

P.T.O. shafts. Spider kits. Input shafts. Output shaft Gears. And other components.

Crown wheel and tail pinions. Rear axle. Intermediate shafts. Lay shafts. Sliding gears.

CASTING PHASE OF Q.C.

In the casting phase of the Q.C. all the casting are visually inspected for the flaws, blows holes and other external defects. Then there over all dimensional criteria are inspected as per there drawing requirements specified in the drawing. For over all aspects affective dimensional accuracy and surface finish of casting are checked. The over all dimensions such as length, height, width, P.C.D., center distance, outer dia, inner dia, fitness or matting, depth and other dimensions are checked with the help of proper instruments. Inspection of the casting for the proper fitting, meshing and etc. with other components to avoided leakage of oil, vibration and etc. Castings are the main part of the tractor. So inspections of it are very important. For front axle beam the gauge is used to check their P.C.D., hole diameters and other parameters. For trumpet housing height gauge, plug gauge, V.C. and other instruments are used to check the other parameters.

The main parts are in this phase are: Seal carrier. Brake housing Brake disk Cover P.T.O. Front axle bracket Wheel front Wheel rear Rear bracket. Sensor tube. Position actuator shaft. Ram cylinder. Ram arm. Piston. Draft actuator shaft. Links And other components.

49

ALLOY STEEL AND FORGING PHASE OF Q.C.

In this phase those forged and small components are made of alloy steel are check as per their drawing. The grinded components are inspected in microns and the forged components may be inspected in mm .The cross-fitted on bench center to check their run out with help of plunger dial with hand rotation and also checked the other diameters. For stub axle its angle is checked with the bevel protector that fitted on the vernier height gauge, outer dia. with micrometer, key off set and other dimension criteria. For steering arm single and double fixture is used to check its dimensions, length and etc. For gear shifter rod for first, seconded, third and forth micrometers are used to check its outer diameter and height gauge for length and etc. Forks are checked with help of fixtures.

The main components are

R.V. housings. Response valves. Brake paddle shafts. Clutch actuator guides. Forks. And other components. Filter pipes. Clutch actuator shafts. Actuator forks. Idler gear shafts. H-L shifter levers.

FABRICATION PHASE
In this phase of the Q.C. the fabricated components are checked as per their drawing specification. The checking of the fabrication components is very necessary because of the mating with other components. For front beam axle its angle is measured with help of the bevel protector hinged on the height gauge and length is measured with V.C.For front axle beam the fixture is used to measure its parameters. Lower link is visual inspected. The main parts are Leveling rods. Angle plate. Hooks. Position sectors. Draft cranks. Draw bars. Bumper. Rocker links. Battery boxes. Position cranks.etc.

50

HARD WEAR BOUGHT OUT PHASE

In this phase the nuts, bolts, studs, washer and etc. are bought from out side are inspected. Bolts and studs are checked with help of the thread ring gauge. For nuts the plug gauge is used to check their pitch. Washers are visual inspected.

STANDARD ROOM: It is the main phase of the Q.C. shop. In standard rooms the damage instrument are repaired. Instruments are also calibrated with there standard. The new made gauges are also checked as per their drawing dimension criteria. For checking the following instruments are used in the S.T. room. Sine center. Height gauge. Dial gauge calibration system. Slip gauges. Bore gauge. Measuring jaws. Sin bar. V.C. Master cylinder. Puppy dial gauge. Comparator stand. Jacks.

51

TRACTOR ASSEMBLY SHOP

INTRODUCTION: Tractor assembly shop is main shop of sonalika international tractor Ltd. In this shop the different machining parts, housing and other components which are finished or machined in other departments of the industry and other component which are purchased from outside are assembled here. Then assembled components like differential housing, gearboxes, rear covers, Trumpet housing and other housing are send to main line for Tractor assembly. In main Tractor assembly line tractors are send to paint shop through overhead endless chain rotating conveyor. It is supported from ceiling and has a fixed path to travel which saves valuable floor space. The arrangement is such that lifting mechanism (with help of hook) lowers down for loading and unloading of tractors. Following are main phase of assembly: -

(1) Differential housing assembly. (2) Gear box assembly. (3) Rear cover assembly. (4) Main line assembly phase (5) Paint phase. (6) Assembly of accessories and inspection

52

DIFFERENTIAL HOUSING ASSEMBLY PHASE

It is rear part of the tractor cheesy. The main function of differential in tractor to reduce the final speed and also to turn the drive round at 90 degree. The reduction of speed is done in two stages. First stage reduction in tail pinion and crown wheel meshing and second stage reduction in shaft (Power take off shaft), which is used to run the thrashers, pumps and other accessory components with the help of pulley attached to it.

. Following are main parts: - of differential housing

(A) Crown wheel. (B) Tail pinion.

(C) Cage assembly. (With sun, planet gears and cross) (D) P.T.O. shaft. (F) B.P. shaft right. (H) Bevel gears. (J) Bearing cones. (E) B.P. shaft left. (G) Bull gears. (I) Bearings. (K) Brakes housing assembly

(L) Oil seals, gaskets and fasteners etc.

53

ASSEMBLY OF CASE CROWN WHEEL: -

First components are washed with oil to remove the dirty particles. Cage having two dowel holes in these holes dowels is tightening fitted for accurate fitting of crown so that all other holes of cage and crown come into same line. The crown wheel is pressed on cage with hydraulic press and then tightens by bolts with lock washer. Then right bevel gear is placed on their cage seat. The four planet gears are put on cross with washer and then this assembly put on their placed on cage. Then placed left bevel gear on planet on gear. Operator to check the motion of gears does manual inspection. Cage left is placed on left side of right cage assembly and then tightens by bolts and washer.

TAIL PINION ASSEMBLY: -

First in T.P. assembly, the cone for taper roller bearing is pressed with hydraulic press. The bearing is heated before the tight fit. Then tail pinion is inserted inside bearing. The diff. size shims are also placed before the tighten of rear cover of cage. Whole assembly is tightening by nuts and bolts.

REAR AXLE ASSEMBLY: -

In rear axle assembly of tractor the bolts are tight fitted in holes of hub. Where the rear tire is tighten with their bolts to whole assembly. For tight fitting the hydraulic press is used and 120-kg\cm sq. forces is apply. Two bearing either side of trumpet housing are tighten at their respective place of cone. The rear axle is passed through these two bearing with seal in trumpet. The cove is used to cover the open side of trumpet housing (hub side). The inner side bearing is lubricated with oil and outer bearing is lubricated with grease.

54

BRAKING ASSEMBLY: -

This tractor having heavy duty Self-energizing, water sealed disc with spherical roller and ventilation pipe which gives better cooling. The ventilated results in reduction of about 30% in pad temperature. Brake housing cover contain two disc made of asbestos base non-metallic. The max. Temp. Resistance about 300 degree C b\w these two disc plate a cast iron plate is fixed which contain steel spherical roller and hold by spring. When ever brake is applied the spherical roller move or lift from there place in the plate and try to expanded the plate. During expanding of C.I. plate the disc are strongly mounted on B.P.left and B.P. right shaft to stop the speed of differential. It also having actuators and link with rubber seal.

P.T.O. SHAFT ASSEMBLY: -

Two bearings are tightly fit on P.T.O.shaft at their proper placed with help of circlip lock, which provided on both side of bearing first of all the P.T.O. shaft assembly is pass through rear P.T.O. hole of differential housing. Then two cones are one on B.P. left and other on B.P. right shafts hole side inserted tightly. The B.P. left and right shaft assembly is placed through their hole then cage housing of differential is placed b\w left anted right B.P. shaft. The seal carrier with different size of shims is tightening by bolts on both side of differential housing (right and left B.P. shaft side). Then pre loading test is done with 10 kg force to rotate the cage assembly. If pre load force is increase the efficiency of taper bearing is decrease due to over friction b\w cage of bearing if decrease pre load force then the efficiency of taper bearing also decrease due to less contact with cover cage of bearing. Then tail pinion assembly is inserted in to respective hole with shims and tail pinion teethes meshed with crown wheel teethes.

Following three testing is done: (A) Back lash testing. (B) Pattern test

55

BACK LASH TESTING: -

This test is performed with help of plunger dial gauge. Backlash in crown wheel is not more then 20 to 30 micron if it is deviated from this value then packing is change on either side (left or side) of cage of bearing housing. But never change the number of shim. If backlash is more then 30 micron then shims from right side is removed and shifted in to left side. If it is less then 20 micron then vice versa.

56

PARTS OF DIFFRENTIAL

DIFFERENTIAL PARTS:

1) Tail pinion: It transmits the power from the output shaft of gearbox to the crown wheel.

2) Crown wheel: It gives housing to the cage assembly where differential action takes place.

3) Differential cage: It gives housing to the spider kit i.e. cross, star, sun pinion.

4) Cross: Its remains fixed in cage assembly and support the motion of the star pinion.

5) Star pinion: Distributes the power between sun pinion according to load applied by them. Consist four-star gear.

57

6) Sun pinion: Transmits power from star pinion to bull pinion shaft. Consist four-star gears.

7) Bull pinion shaft: Gives power to the bull gear and bear the action of break.

8) Bull gear: Transmits power from bull pinion shaft to rear axle. 9) Rear axle: Transmits power from bull pinion shaft to rear wheel. 10) Differential lock: Differential lock is made on bull pinion shaft a hollow shaft and
we provide an extra coupler assembly in differential. When differential is free from lock the coupler are in disengaged position and when we apply the differential lock couplers are in engaged position.

11) Brakes: - In differential, we use two kinds of brakes according to HP (Horsepower)

of tractors and specifications by customer.

1) Dry brakes. 2) OIL Immersed brakes.

1) Dry brakes:- In a dry brakes two discs and two break liners are assembled along With steel balls in brake housing. It is attached with rocker shaft assembly when brake is pressed than rocker shaft stops bull gear and rear wheels get stop. In tractors mechanical brakes are employed. In dry brakes, wear and tear of disc is more because heat dissipation is more due to friction and cooling is less.

2) OIL Immersed brakes:- OIL Immersed brake consists of a housing bolted to the vehicle frame containing four discs with an actuating assembly between the two discs. The discs have lining material on each face and a splinted shaft running through the housing drives them. The actuating assembly is composed of two plates separated by hardened steel ball located in recess in the plates, and the assembly is held by short springs. The lugs on the actuating plates are connected

58

to the yoke or jaw end on the pull rod by two links. In oil immersed brakes wear and tear is less as compared to dry brakes

GEAR BOX ASSEMBLY

Types of gears used and assembled in plant:-

SLIDING MESH GEAR

In this transmission, the power comes from the engine to the clutch shaft and hence to the clutch gear which is always in mesh with a gear on the lay shaft. All the gear on the lay shaft are fixed to it and as such they are all the time rotating when engine is running and clutch is engaged. Three direct speeds and one reverse speed are attained on suitably moving the gear on the main shaft by means of selector mechanism. In tractor, we are providing extra planet carrier for HI-LOW. In a High low gear, we provide one internal gear with sleeve that accomplish the engagement and disengagement of high and low gears. In a sliding, mesh gears Spur gear are used so gears can easily slide as well mesh to each other so power can distribute according to the gear ratio. 59

CONSTANT MESH GEAR BOX

In this type of gearbox, all the gears of the main shaft are in constant mesh with the corresponding gears of the intermediate shaft. Two dog clutches are provided on the main shaft-one between the clutch gear and the second gear, and the other between the first gear and reserve gear. The main shaft is splined and all the gears are free on it. Dog clutch can slide on the shaft and rotate with it. All the gears on the counter shaft are rigidly fixed with it. When the left hand dog clutch is made to slide to the left by means of the gearshift lever, it meshes with the clutch gear and the top speed gear is obtained. When the left hand dog 60

clutch meshes with the second gear, the second speed gear speed is obtained. Similarly, by sliding the right hand dog clutch to the left and right, the first speed gear and reserve gear are obtained respectively. In this type of gear box, because all the gear are in constant mesh, they are safe from being damaged and unpleasant grinding sound does not occur while engaging and disengaging them. In tractors, we are providing the hi-low shaft for variation in power. During HIGH, the power coming from the transmission is direct send it to differential through the hi-low intermediate shaft. During low, the power is first transmitted to hi-low lay shaft or counter and then it is transmitted to the differential. Following are the main components of gearbox: -

(a) Input shaft assembly. (c) Lay shaft assembly. (e) Actuator shaft ass. (g) Gear box housing. (i) Shifter forks. (k) Fastness, gaskets and spacers.

(b) Output shaft assembly. (d) Intermediate shaft assembly. (f) Gears. (h) Shifter rods. (j) Bearings.

(l) Planet gear and carrier ass. with internal gear.

CLUTCH ACUTATOR (C.A.) ASSEMBLY: C.A. assembly contains clutch actuator guide on which the bearing is tighten fitted and locked with circlip. Inner bush is placed and hold it with C.A. guider springs. LAY SHAFT ASSEMBLY: The lay shaft is hollow shaft with splines on outer surface.The one end of the lay shaft is threaded (in case of single clutch) and tightened from front side of gearbox with a hexagonal nut. The whole assembly consists of gear Z-45 (i.e. constant mesh gear with input shaft gear) spacer 15mm, gear Z-36, gear Z-30, spacer 30mm, gear Z-25, spacer 25mm and bearing with circlip. The whole ass. is washed. In case of dual clutch tractor model the drive shaft is placed through the hollow lay shaft. The drive shaft consists of splines on one end and a gear (Z-45) on the other end. The gear constantly meshed with 61

the gear of intermediate shaft. The main function of lay shaft is to rotate fixed gear on it from where we can get different speeds with the help of sliding gear on drive shaft. INPUT SHAFT ASSEMBLY: Input shaft consists of spiral gear on one end and splines on the other end. Splined part is attached to clutch and geared part (Z-19) is attached the constant mesh gear of lay shaft i.e. Z-45. Input shaft is put in to the gearbox with the bearing, which is locked by circlip.

OUTPUT SHAFT ASSEMBLY: Output shaft assembly is solid shaft with splines on outer surface. The shaft is placed in to gearbox with both ends supported by bearings and locked by circlip. The back part of shaft is projected out side the gearbox to get drive from it. The assembly of shaft Consist ideling gears 24, 31 and 34 gears

INTERNAL GAER ASSEMBLY: On internal gear two dowels are inserted at their proper place and faceplate with thrust plate is placed over dowels. The purpose of the dowels is to locate holes on the plate w.r.t internal gear. The planet carrier contains three planet gears, which are fixed to carrier with, help of pins inserted through them. The planet gear and carrier assembly is placed inside the internal gear them thrust plate and outer plate is placed and tightened by nuts.

ASSEMBLY OF GEAR BOX: First of all the gearbox is placed over the trolley which is continuously moving with the help of the chain system. The idler gear is placed with their idler gear shaft in gearbox its respective place. Then lay shaft assembly is inserted into the respective holes and tightened from front side by hexagonal nut. After this input shaft is placed front side of the gearbox housing. Its Z-19 is meshed with C.M. Z-45 of lay shaft. Then the output shaft assembly is placed into the gearbox where its one side is inserted into the input shaft hole. For D.C. models the intermediate shaft, which is hollow, placed over the input shaft

62

and its Z-21 gear is meshed with Z-43 of connecting shaft, which placed through the hollow lay shaft. The internal gear assembly is tightened on the outside of gearbox with output shaft. The four selector rods are placed in the holes with springloaded ball. The gear selector forks are inserted in to the groove of sliding gears and then tightened to the gear shifter rods with help of the bolts. The forth selector rod is meant for low and high-speed selection. This rod is connected to the drive shaft, which is placed into the internal gear. Then Z.F. cover bracket is placed over the upper side of the gearbox. Z.F. cover plate is consists of the steering assembly and high, low speed shifter assembly. Then whole assembled gearbox is send to the main line assembly.

DUAL CLUTCH ASSEMBLY: In some agriculture equipment like potato cultivator etc required continuous power from P.T.O. shaft but in single clutch it is not possible because when we press clutch it slow down the speed of tractor. The lay shaft is disconnected which further stops the working of P.T.O.shaft, which is connected to the lay shaft but in double clutch intermediate shaft is placed over the input shaft, which is connected to the connecting shaft through gear Z43. The power in this case is transferred through connecting shaft. Now two clutches are there which have different setting on clutch lever. The first press of the clutch will stop the power transmission to lay shaft through input shaft, which further stops the power transmission to the differential, but seconded clutch is connected to the intermediate shaft, which transmits the power from connecting shaft to P.T.O. shaft.

63

REAR COVER ASSEMBLY

Rear cover assembly is used to cover the differential housing. It contains lift control system, which is hydraulically operated. The response valve housing (R.V.) control valve, cylinder and other components assembly fitted inner and outer side of rear cover assembly. The main components are fitted in rear cover assembly

(a) Control valve assembly.

(b) R.V. housing assembly.

(c) Hydraulic cylinder and piston assembly with lift arm. (d) Operating sector assembly. (f) Gaskets, bolts, nuts. (e) Sensor tube assembly. (g) Other components

64

RAM CYLINDER ASSEMBLY: It contain cylinder for single lever with piston inserted in side the cylinder. The relief valve assembly is mounted at top front of cylinder. The connecting rod is placed in piston rear side ands one side is locked with ram arm assembly. A rock arm, spacer and seals are placed. At the end of rock arm assembly lift arm assembly is placed on the splinted and then locked with bolts on both side.

R.V. HOUSING ASSEMBLY: It contain the response valve which having different valves and components are placed at their respective place. It contains one response valve, check valve and realize valve. Two dome nuts are placed at their respective place. It is also connected with control valve through pipe housing. The knob is placed at top of response valve to close or open the response valve as per requirements.

CONTROL SECTOR ASSEMBLY: It contains the draft crank assembly, which is placed through the hollow position crank assembly. Both these assembly are connected to their lever. The position crank assembly is connected to black mark lever and draft crank assembly is connected to red mark lever. All assembly is fastened with bolts, nuts, washer and locknuts.

COUPLER ASSEMBLY: In coupler assembly a draft rod having a flange and position rod contains spring on it. Draft rod assembly is connected to the draft lever and position rod to position lever through the control valve. Whole assembly is fitted inside rear cover. First of all rear cover is mounted on the moving trolley and tight with bolts. The control sector assembly is placed at there respecting place with actuator shaft and compiler assembly. A sensor tube with burn is placed at rear side of rear cover. Then a ram cylinder assembly in haunted inside rear cover.R.V.housing is placed out side rear cover, which is connected to control value through pipes. All other components assembly is a 65

placed their respective place control value container three value i.e. Back measure value (3-6kgf) unloading value and scroll value. When oil from pump goes into R.V.housing through pipes, which is further connected, to the check value through inner hole of R.V.housing and Backpressure value of control values. The opening pressure of check value is 9-12kgf and opening pressure of backpressure value is 3-6kgf. During unoperated position the oil is continuously. Through the backpressure value of control valve.

During operating of position arm the unloading valve close the gallery of oil to back pressure valve. Thus the pressure in R.V.housing built up which open the check valve at 9-12kgf. As this position the oil goes in the Ram cylinder, which further operate the lift arm. For required of any position lift the knob of response value of R.V.housing is rotate which cut the supply of oil and the position of ram arm is got. Sensor tube is work in field working during ploughing of shaft nature soil with harrow and when harrow deeply dug in soil, which over load the tractor. But to avoid deeply dug of harrow in

FRONT AXLE ASSEMBLY

Front axle is fitted at the front of the tractor and the two stub axles fitted at either end through which the steering linkage is connected and wheels are steered. Its is one of important parts of tractor as front wheel are attached and steered with help of steering linkage so . ts support the front parts.

66

PROCESS CHART OF FRONT AXLE

MAIN LOOP CHASSIS In line phase assembly all the components are assemble together. Firstly the differential housing assembly is put on moving trolley, which is connected over the conveyor. Then the gearbox assembly is joining with help of bolts to differential housing and then accessory and mounting is joined. Two lower links (LT. and RT.) are join with link plate. The anchor chain attached with angle plate (with attached to diff. rear side) and lower side attached with lower link hook. The lift rod upper and right leveling rod assembly is attached with arm of rear cover. Two straight bars are attached with trumpet housing and lower side link for

Then engine assembly is attached to gearbox assembly with nuts and bolts. At front side of engine assembly the front axle beam assembly is fitted. In axle beam assembly pivot pin is placed at their hole with thrust washer and the front axle bracket is attached with axle beam Assembly with nuts and bolts. Two king pin stub axle assembly (LT. and RT.) are placed in front axle beam assembled with their steering arm (LT. and RT.) tie rod end (LT. and RT.), tie rod assembly, steering arm, hub, and wheel rim front (LT.and RT.) and other components. Whole brake assembly's fitted on tractor and connected with brake housing through mechanical links. Then clutch assembly is placed at their place.

67

FINAL ASSEMBLY
PROCESS FLOW OF TRACTOR ASSEMBLY LINE

Fuel tank frame, fuel tank along with cork and fuel supply system. Radiator& fan fitment. Electrical harness fitting. Fender mounting. Diver seat fitment. Stay bar and tension spring and anchor chain fitment. Rear and front wheel fitment. Bonnet, bumper, grill meter plate and horn plate fitment . Diesel, transmission oil filling. Pre cleaner fitting. Air cleaner fitting. Line inspection.

68

ROLLER TESTING

Place the tractor on the roller. Tie up the tractor with the hook provided for it. Remove one end of draw bar and insert the end of the chain weight in it. Run the tractor at idle rpm for 5-7 min. Gradually increase the rpm to the full throttle for 15min. After this, check all joints and leakages from the pumps. Check all the shifting of the gears and run them for 1-2min. Check hydraulic lift is working by lifting the weight. During running at idle rpm and full, throttle rpm check all the meters on dashboard whether they are working properly or not. Unhook all the chain and hook from the rear. Hang the weight chain back on their place. Remove the tractor from the roller. Check left-right hand brakes separately on the road.

69

ADJUSTMENT OF TOE-IN

Toe-in should be between 2mm to 6mm. Adjust the toe in of the tractor by adjusting the length of the track rod using spanner of 24mm.

ADJUSTMENT OF CLUTCH PEDAL

Adjust the free play of the paddle it should be between 20mm to 25mm. Adjust the free play of clutch pedal using the spanner of 14mm.

ADJUSTMENT OF BRAKE PEDAL

Adjustment of the brake pedal, it should be between 55mm to 65mm. Adjust the free play of the brake pedal from the screw-using spanner of 17mm.

Checking of differential

Check abnormal noise in forward running at engine RPM 1800-2000. Check for abnormal noise in forward and backward running at 725 -1000 rpm. Check any abnormal noise from spider kit while driving left and right.

Checking of gearbox.

Check proper engagement of gears while driving. Check any noise from gear while driving it following gear ratios.i.e.

70

Checking of engine

Check engine oil pressure at 725-750 rpm > 0.5 kg/cm. Check engine oil pressure at 2150 2200 rpm > 0.5 kg/cm < 4.5 kg/cm. Temperature of water in working condition 70 to 80c

Checking of hydraulic problem

Check hydraulic arms for self-rising Check hydraulic lift at idle rpm .is it support the load or not. Checking of vibration at full rpm in hydraulic arm. Checking for jerking problem while lifting load. Checking a noise from sensor while lifting. Checking a noise from rocker shaft. Checking of response valve.

PTO SHAFTS CHECK POINTS

All double clutch (DC) models = 06 splines. All single clutch 540 rpm = 06 splines. All models above than 50 hp and four cylinder = 06 splines. All models below 50 hp = 21 splines.

71

CONCLUSIONS AND FUTURE SCOPE OF TRAINING

Conclusions And Future Scope

The professional and training atmosphere at INTERNATIONAL TRACTORS LTD. has helped to develop special skills like punctuality, to work under extreme pressure and at critical times etc. in us. Working on live projects in company like ITL is really a big experience where every person is always there to help the trainees, by providing us the time from their busy schedule.

The training was a real exposure for a layman to the automobile industry, and above all it was informative.

All in all, it was an enriching, resourceful, informative and above all led to lot of exposure for our practical skills

72

73