PREFACE

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























COMPANY PROFILE

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

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

Escorts has been a major player in the railway equipment business in India for nearly five
decades. Our product offering includes brakes, couplers, shock absorbers, rail fastening
systems,composite brake blocks and vulcanized rubber parts.
In the auto components segment, Escorts is a leading manufacturer of auto suspension
products including shock absorbers and telescopic front forks. Over the years, with
continuous development and improvement in manufacturing technology and design, new
reliable products have been introduced.
Throughout the evolution of Escorts, technology has always been its greatest ally for
growth. In the over six decades of our inception, Escorts has been much more than just
being one of India's largest engineering companies. It has been a harbinger of new
technology, a prime mover on the industrial front, at every stage introducing products and
technologies that helped take the country forward in key growth areas. Over a
million tractors and over 16,000 construction and material handling equipment that have
rolled out from the facilities of Escorts, complemented by a highly satisfied customer
base, are testimony to the manufacturing excellence of Escorts. Following the globally
accepted best manufacturing practices with relentless focus on research and development,
Escorts is today in the league of premier corporate entities in India.

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

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



THE FOUNDING PHILOSOPHY

Over six decades back two young men set out on a journey together armed with little
beyond intelligence, business acumen and determination and dreams aplenty. They
believed that India could only achieve total freedom with a breakthrough in the field of
agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had
kindled the hope that one day they would make a mark of their own. They were in fact
writing the first chapter of what has come to be widely recognized as one of the greatest
success stories in Indian industry.
Escorts came into being with a vision. A vision that eschewed easy paths to profitability,
and sought instead for ways to make a contribution. A vision that led two young brothers,
Yudi and Hari Nanda, to branch out of their family's prospering transport business and
institute ventures that were to become the foundations of Escorts Limited. On 17th
October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi
Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting
marketing house driven by the same business philosophy, which had given their family
enterprise an unrivalled reputation: customer concern. Not long afterwards, this driving
ambition to go beyond the expected led Hari Nanda to the first of his many successful
business insights - the discovery of the great business potential that lay in India's villages.
This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda
as Director. Though separate business entities then, both companies had two great
strengths in common: the dynamic Nanda brothers and the unifying force of the name they
gave their companies; Escorts, literally 'escorting' their products and services to the
customer while most other businessmen were just selling.
Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit remained embedded
in the foundations of the company. Mr. H P Nanda then took on the mantle to realize the
dreams which he had always seen with his brother.
Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged in 1953 to create
a single entity -Escorts Agents Pvt Ltd. Having initially started with a franchise for
Westinghouse domestic appliances, by this time the Company had already expanded its
marketing and service operations, representing internationally known German and
American organizations such as MAN, AEG, Haniel&Leug, Knorr Bremse, MIAG and BMA for
sophisticated electrical and mechanical engineering equipment and Minneapolis Moline
and Wisconsin for agricultural tractors, implements and engines. Escorts made a major
thrust into the agricultural arena by taking on the marketing and service franchise for
Massey Ferguson tractors in Northern India, which soon comprised 75% of MF's all-India
sales - a signal tribute to Escorts' inherent strengths. Its first industrial venture came up in
1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings and
cylinder liners - followed by production of pistons in collaboration with MAHLE, also of
Germany, in 1960. The company's incorporation in its present name, Escorts Limited, was
effected on 18th January, 1960. Escorts' next major industrial activity was the assembly of
tractors in 1961 in technical cooperation with URSUS of Poland. Subsequently this led to
the manufacture of the country's first indigenous tractors under Escorts' own brand name,
which were to play a pivotal role in the Green Revolution. This went on to lay the
foundations that even today are the Company's core strengths -relevant, world-standard
technology through strategic international alliances; a broadbased marketing and service
network yet unrivalled.

Beyond the growth of the organization, these principles have ensured that Mr. H. P.
Nanda's contribution to the cause of industry and the consumer will endure. He pioneered
the revolutionary concept of 'interdependence' between ancillary and large industries,
institutionalizing vendor development and in the process building Faridabad and the entire
belt of townships in the region. He introduced the discipline of service going before
marketing, reassuring the customer that Escorts would stay with them, that they were here
for the long run. He built lasting alliances with an array of the world's most respected
names in tractors, industrial equipment, two-wheelers, construction equipment and
telecommunications. Going further, he created institutions devoted to value engineering
and training, not only as investments in the company's future but also as catalysts for the
enhancement of Indian industry as a whole the Escorts R&D Centre and the unique Escorts
Institute of Farm Mechanization. His concern extended to the society in which he worked,
and he manifested it by establishing the Escorts Medical Centre at Faridabad, Escorts Heart
Institute and Research Centre at New Delhi, as well as numerous village development
programmes. And above all, he imbued the corporation with his own pioneering.

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












Background



In 1960, our parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to
venture into tractors.


In 1965, we rolled out our first batch of tractors under the brand name of Escort.



In 1969 a separate company, Escorts Tractors Ltd., was established with equity
participation of Ford Motor Co., Basildon, UK for the manufacture of Ford agricultural
tractors in India.



In the year 1996 Escorts Tractors Ltd. formally merged with the parent company, Escorts
Ltd.


Since inception, we have manufactured over 1 million tractors.








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

Component Plant
Tractor Assembly Plant
Crankshaft & Hydraulic Plant

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

Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics
Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are
being machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal
Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where
critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being
machined and assembled. It has State of the Art Honing and other precision machines.




Overview Materials Management

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
























METHODS INVOLVED IN
THE PROCESS OF
PRODUCTION OF REAR
AXLE





DESIGN OF THE REAR AXLE SHAFT






REAR AXLE PRODUCTION UNIT
S. No OPERATION
DESCRIPTION
MACHINE
EQUIPMENT
OPERATION CYCLE
TIME(MINUTES)
1 FINISH TURNING
OF BIG END
FLANGE
NCL-15; NCL-16
KWS MAKE CNC
LATHE
1. DRUM DIA
2. BIG END FLANGE DIA
3. LENGTH OF DRUM
DIA
4. FLANGE WIDTH
5. LENGTH OF SEAL DIA
6. LENGTH OF BEARING
DIA
7. THREAD SIZE
8. THREAD LENGTH
9. LENGTH OF SPLINES
10. LENGTH OF SEAL DIA
11. STEM DIA
12. FILLET RADIUS OF
STEM TAPER DIA
13. SURFACE FINISHING
OF STEM TAPER DIA
8.99(57 JPS)
2. DRILL AND FINISH
HOLE MILL 8 NOS
BOLT HOLES
THROUGH AND
DRILL 2 NOS
MANUFACTURING
HOLES
HMD-19
BATLIBOL MAKE
MULTIDRILLING
MACHINE
1. BOLT HOLE DIA
2. BOLT HOLE CO-
ORDINATES
3. MANUFACTURING
HOLE DIA
4. MANUFACTURING
HOLE CO-ORDINATES
4.25(124 JPS)
3. FORM OIL
GROOVE ON
STEM END FACE
ETL-01 1. OIL GROOVE DEPTH
2. OIL GROOVE PROFILE
3.43(140 JPS)
4. CHAMFERING OF
BACK FACE OF 8
NOS BOLT HOLES
VLM-03 1. CHAMFER DIA
2. CHAMFER ANGLE
3.43(140 JPS)
5. MILLING OF 38
INVOLUTE
SPLINES ON STEM
END
SMM-02
HURTH MAKE
SPLINE MILLING
MACHINE
1. NO OF SPLINES DIA
OVER MEASURING
PINS.
2. PCD RUNOUT
3. LENGTH OF SPLINES
3.55(104 JPS)
6. WASHING OF
COMPONENT
WSM-01
THERMAS
MAKE
1. EFFECTIVE CASE
DEPTH ON STEM
2. EFFECTIVE CASE
5(80 JPS)
WASHING
MACHINE
DEPTH TOWARDS
FLANGE DIA
3. EFFECTIVE CASE
DEPTH AT REST DIA
OF SPLINES
4. EFFECTIVE CASE
DEPTH AT ROOT OF
M-642 THREADS
5. HEAT RUNOUT ON
SPLINED END
7. INDUCTION
HARDENING OF
SHAFT STEM
IHM-03
IHM-04
1. QUENCHING MEDIA
2. TEMP OF
QUENCHING MEDIA
3. PRESSURE OF
QUENCHING MEDIA
4. RADIAL GAP B/W
INDUCTOR &
COMPONENT
5. FACE GAP B/W
INDUCTOR AND
COMPONENT
6. QUECH LAG TIME
7. PRE HEATING TIME
8. POWER REQUIRED
9. SPINDLE SPEED
10. INDUCTOR
TRANSVERSE RATE

8. CHECK FILE
HARDNESS AT
NECK & STEM

9. NORMALISE THE
SHAFT IF
REQUIRED FOR
REWORK
IHM-04
INDUCTION
HARDENING
MACHINE

10. FLANGE
HARDENED STEM
AND FACE
FLANGE
HARDENING
EQUIPMENT

11. TEMPER THE
INDUCTION
HARDENED SHAFT
TFF-04
TFF-05
TEMPERING
FURNACE
SURFACE HARDNESS TEMP OF
TEMPERING
TEMPERING
PERIOD
12. STRAIGHTENING
OF SHAFT STEM
HDP-05
BEMCO MAKE
HYDRAULIC
PRESS
RUNOUT ON 47 INVOLUTE
SPLINE DIA

13. GRINDING OF
SEAL DIA & FINISH
GRINDING OF
BEARING DIA &
BEARING SEATING
FACE
AGR-07
ANGULAR HEAD
GRINDER
1. SEAL DIA
2. BEARING DIA
3. SURFACE FINISH ON
BEARING DIA
4. DIST OF BEARING
SEATINGFACE FROM
FLANGE FRONT
3.45(139JPS)
14. FINISH GRINDING
OF SEAL DIA
ANGULAR HEAD
GRINDER
AGR-05
LENGTH OF SEAL DIA
SURFACE FINISH OF SEAL DIA
2.91(165 JPS)
15. FINISH GRIND
STEM AND FACE
MTC-01
FACE GRINDING
EQUIPMENTS
1. SURFACE FINISH OF
STEM END FACE
2. LENGTH OF STEM
END FACE wrt
BEARING STEATING
FACE
4.21(132 JPS)
16. SUPER FINISH OF
SEAL DIA
SFM-02
SUFFINA MAKE
SUPER
FINISHING
MACHINE
1. SEAL DIA
SURFACE FINISH
OF SEAL DIA
2(132 JPS)
16. CHECK CRACK ON
REAR AXLE SHAFT
MAGNA FLUX
CRACK
DETECTOR
1. FREE FROM
CRACKS

17. FINAL
INSPECTION OF
SHAFT REAR AXLE
STAGE 2. AS PER PART
PRINT
SPECIFICATION
2(132 JPS)






































OPERATIONS PERFORMED
FINISH TURN SHAFT REAR AXLE AND CUT THREADS



MACHINE TYPE- NCL-15;NCL-16

CUTTING PARAMETERS:-
TOOL NO FEED SPEED
06 0.016/0.20 750ft/mtr
07 0.006/0.12 750ft/mtr
0101 0.0787/RN 650ft/mtr
04 0.012/RN 700ft/mtr


GAUGE USED

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






















TESTING SHAFT RUNOUT CHECKING AFTER CNC



OPERATERS PROCEDURE(BENCH CENTRE)

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


TO DRILL AND REAM 8 BOLT HOLES ON FLANGE





DRILL TWO MANUFACTURING HOLES.

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






DRILLS USED- 4235AA-ET-85A


HOLE MILLS- 4235AA ET 86A
4235AA EG 27
7235 AA EG 4

LIMIT GAUGES- G-40088
G-40087


OIL GROOVE ON STEM END FACE



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


GAUGE TO CHECK 4235 AEG 6


CHAMFER ON 8 HOLES






CHAMFER SIZE - .070+ 0.10X45

CHECKING FREQUENCY- 1/160

TOOL USED-TS COUNTERSUNK CUTTER DIA 3/4X90





FINISH MILL 38 & 47 INVOLUTE SPLINES







TOOL & M/C SETTINGS-
CUTTER- 4235A ET 83(FOR 47 SPLINE)
REEMER - 4235A-ET 9(FOR 38 SPLINES)
FACE CENTRE - 4235AA EF 44/1
TAIL STOCK CENTRE - MA-321/25

GAUGES USED-
4235 EG 71
4235 AEG 29
4235 AEG 28
4235 AEG 72

SPEED - 180 RPM
FEED - 400M/MIN




SHAFT INDUCTION HARDENING


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




TEMPER INDUCTION HARDENING OF SHAFT

FURNACE TEMPERATURE- 230C-240C
TIME PERIOD- 1.5-2.5 HRS

CHARACTERISTICS-
CHANGE OF BASE COLOUR TO GOLDEN COLOUR.


GRIND SEAL DIAMETER

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



FINISH GRIND SEAL DIAMETER









TAPER CUT GRINDING WHEEL :- 100/68X40X31.75

SUPER FINISH SEAL DIA :- 2.105/2

STONE USED :- 60mmX60mmX18mm

OSCILATOR DRIVE PRESSURE :- 1.5 2.5 BAR.



STAGE INSPECTION


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


CRACK CHECKING(MAGNA FLUX)




CURRENT RATING :- 2200-2800 AMPS

IF BLUE LIGHT SHOWS THEN PIECE IS REJECTED OTHERWISE PASSED WITH OK SIGN.


Bibliography


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