2014

KCC INSTITUTE OF TECHNOLOGY & MANAGEMENT

GREATER-NOIDA


Administrative Office and Components Plant
18/4, Mathura Road, Faridabad 121 007
ESCORTS LIMITED
Construction equipment

SUBMITED BY NITESH KUMAR SHARMA
Roll no.-1149240066
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Acknowledgement







I would like to thank to all those with whom I worked and whose
thoughts and insights helped me in increasing my knowledge and understanding of
working in the organization. I would like to pay my sincere gratitude to MR. ram
& all employees, who helped me during the course of my training by providing his
valuable suggestion, ideas and guidance which proved beneficial for completion of
my training.

Besides I would also thank to my HOD Sir Mr. Rakesh Kumar Porwal
who gave a guru mantra and said keep in touch with workers so that u
learn fast and make them as your family member and really they helped
me to understand the depth of my training. These people made me
comfortable to understand the functioning of each machine & about the
operation occurring on the machines.

They tried their best to make me understand about the fixtures, tools and gauges
used on the machine. These peoples never made me feel as a trainee in the
department rather provide an atmosphere like a family and feel proud being the
part of their through for short while. Without their help this training would never
have taken its present form. Lastly, but not least I thank one and all who have
helped me directly or indirectly in completion of the report.

I have been really opportunistic to be a part of the Escort Group during my summer
training, which is one of the leading tractor company in todays scenario.

I am once again, thankful to members of ESCORTS Group for their co-operation.
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Abstract




Practical training is a way to implement theoretical knowledge to
practical use. To become a successful engineer it is necessary to have a
sound practical knowledge because it is only way by which one can
acquire proficiency & skill to work successfully in different industries.

It is proven fact that bookish knowledge is not sufficient because things
are not as ideal in practical field as they should be.

Escorts Ltd. is one of the best examples to understand the production
process and productivity in particular of Tractor and its parts.

This report is an attempt made to study the overall processes Cylinder
block machining. This report presents the Escorts Ltds introduction,
technical collaboration, Products.

Operation on cylinder block is the focused part as it was the department
allotted to me in Escorts agri-machinary group. The machining
processes of cylinder block is carried out at line E4.286 like facing,
drilling, boring, chamfering, turning, finishing etc. The process in layout
of line E4.286 is studied by me during 4 weeks summer internship are
mostly emphasized within this report.







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CONTENTS


Certificate I
Acknowledgement II
Abstract III
List of Abbreviation
Sr. No Chapter name
1 I ntroduction
1.1 About escorts ltd.
1.2 Mission
1.3 Quality policy
1.4 History
1.5 Logo
1.6 Key persons
Agri-Machinery Group
2.1 Features of AMG
2.2 Turn over
2.3 products
2.4 Awards
5

Steady of cylinder block machining
conclusion

List of abbreviations

AMG-Agri machinery group

KMC-Knowledge Management centre




























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Chapter-1

Introduction

In todays competitive world with fast depleting material resource, and with all its
limitations, it has become imperative to develop human resources and its
effectiveness. The continued effectiveness and efficiency of an organization to
some extent depend on the ability of its employees to produce at high levels of
efficiency, and to keep abreast with role, which the job demands. Training should
be a long terms investment in human resources.

1.1 About - The Escorts Ltd.

Escorts Limited is all set to face the future by drawing on its 50 years of
experience, its inherent strengths and a strong presence in the core sector providing
complementary product line and a vast marketing network combining them with
Indias intrinsic cost advantages to become a global source point for high value
engineering products.

In order to meet the challenges in the future and to leave an indelible mark on the
industrial scenario, Escorts has restructured the group along six business lines,
each headed by an independent CEO. The business groups are as follows:-

1. Agri- Machinery Group
2. Construction-Equipment
3. Automotive Ancillaries
4. Financial Services



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1.2 Mission

Escorts Endeavours to transform lives in rural and urban India by
leading the revolution in agricultural mechanization, modernization of
automotive and railway technology, as well as transformation of Indian
construction industry
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1.3 Quality Policy



We shall strive to continuously improve to meet the ever rising
expectation of our customers at the lower cost. Each one of us must fulfill the need
of our customer, both internal and external with the highest degree of commitment
thereby creating a quality organization geared to ensure total customer
satisfaction and the sustained health and prosperity of our business.




1.4 Company History

The genesis of Escorts goes back to 1944 when two brothers, Mr.
H. P. Nanda and Mr. Yudi Nanda, launched a small agency house, Escorts Agents
Ltd. in Lahore. Over the years, Escorts has surged ahead and evolved into one of
India's largest conglomerates. In this journey of six decades, Escorts has had the
privilege of being associated with some of the world leaders in the engineering
manufacturing space like Minneapolis Moline, Massey Ferguson, Goetze, Mahle,
URSUS, CEKOP, Ford Motor Company, J C Bamford Excavators, Yamaha, Claas,
Carraro, Lucky Goldstar, First Pacific Company, Hughes Communications,
Jeumont Schneider, Dynapac .These valued relationships be it technological or
marketing, are our highly cherished experiences treasures, which have helped us
inculcate best in class manufacturing practices and to emerge as a technologically
independent world class engineering organization.

1944 - Launch of Escorts (Agents) Ltd.

1948 - Pioneered farm mechanization in the country by launching Escorts
Agricultural Machines Limited, with a franchise from the U.S. based Minneapolis
Moline, for marketing tractors, implements, engines & other farm equipment.
Launch of Escorts (Agriculture and Machines) Ltd.1949 - Franchise of Massey
Ferguson tractors for northern India.

1951 - Escorts established India's first private Institute of Farm Mechanization at
Delhi.

1953 - Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged
to form Escorts Agents Pvt. Ltd.

1954 - 1st industrial venture of Escorts to manufacture piston rings in collaboration
with Goetze of Germany, in an era when joint ventures of Indian firms with foreign
companies were virtually unheard of.
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1958 - Started importing Massey Ferguson tractors from Yugoslavia for
marketing the same in India


1959 - Collaboration with Mahle of Germany to manufacture pistons. Soon,
Escorts became the largest producer of piston assemblies in India.

1960 - Set up of Escorts Limited

1961 - Setting up of manufacturing base at Faridabad for manufacture of tractors in
collaboration with URSUS of Poland and 50% indigenous components. Launch of
Escort brand of tractors collaboration with CEKOP of Poland for manufacture of
motorcycles and scooters. Escorts moves into high gear by nurturing the two
wheeler culture. The first Rajdoot motorcycle rolls off the assembly line.


1969 - Escorts Tractors Limited was born a technical and financial joint venture
with the global giant Ford Motor Company, USA, to manufacture Ford tractors in
India. The years ahead saw Escorts grow as the largest tractor manufacturer in
India.

Escorts Institute of Farm Mechanization (EIFM) established at Bangalore.

Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial
democracy comes into being.

1971- 1st February, the first tractor FORD 3000 rolled out of the factory. Escorts
diversifies and starts manufacturing construction equipment.

1974 - Crossing national boundaries, Escorts exports for the first time. After
winning a global tender, 400 tractors were exported to Afghanistan, which was
perhaps the world's largest ever airlift of tractors.

1977 - Escorts enters the world of self-developed technology by setting up its first
independent R&D Center. Escorts Scientific Research Centre marked its beginning
at Faridabad by developing its own Engines for E-27 and E-37. Due to constant
technology absorption, indigenization level touched 72% for FORD tractors. 2nd
plant at Bangalore for manufacturing piston assemblies was set up.
1979 - Collaboration with JCB Excavators Ltd., UK for manufacture of excavators.

1980 - Foray into healthcare, Escorts Hospital and Research Center set up in
Faridabad.

1983 - Escorts Tractors Limited (ETL) established a state-of-the-art research and
development centre to spearhead newer breakthroughs in Farm Mechanisation and
to maintain industry leadership. Line concept introduced for engine block
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machining. 11,000 ton floating dry-dock Escorts I launched.

1984 - JV Escorts - Yamaha to manufacture motorcycles.

1984 - Signing of agreement with the Japanese bike giant Yamaha to manufacture
motorcycles with Yamaha technology. Collaboration with Jeumont Schneider of
France to manufacture EPABX systems Collaboration with Dynapac of Sweden to
manufacture vibratory road compactors.

1988 - Escorts Heart Institute and Research Centre (EHIRC), a world class cardiac
care facility launched in New Delhi.

1989 - Joint Venture with Claas of Germany to manufacture harvester combines.

1990-91 - First Public Issue in February 1991, over-subscribed four times. Shares
listed on Delhi and Bombay Stock Exchanges.

1993 - FORD 3620 tractor launched.

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

1997 - Joint Venture with Carraro of Italy for manufacturing and marketing of
transmission and axles. Joint Venture with First Pacific Company of Hong Kong -
Escotel Mobile Communications.

1998 - POWERTRAC series of tractors launched. MoU was signed with Long
Manufacturing Company, USA for setting up a Joint Venture in USA.

1999 - MoU for Joint Venture with a Polish Company POL-MOT was signed for
assembly, manufacturing and marketing of Farm Machinery.

2004 - Divested Escotel Mobile Telecommunications to Idea Cellular TS16949
certification for Agri Machinery Group.

2005 Divested Escorts Heart Institute and Research Centre (EHIRC) to Fortis
Healthcare.

2006 - Divested in Carraro India Ltd.

2008 - ECEL launches Fully Hydraulic Crawler Cranes

2009 - ECEL has recently commissioned its state-of-art manufacturing plant
rolling out pick-n-carry cranes and vibrators compacto
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Company logo













A hexagonal nut (in red) representing a geometric perfection. The nut has been a
functional device that has stayed at the core of mankinds engineering adventures.
In spite of modern technologies coming in, it still remains unarguably a symbol of
technology and all that holds it together. Locked into the nut is a spanner (in
white), the turning force for the symbol of technology. The two pictorial elements
Are configured together to form an 'E', a pneumonic for Escorts.



1.5 Key Persons
Name Designation
Rajan Nanda CEO

G B Mathur Secretary

Hardeep Singh Director

M G K Menon Director

Nikhil Nanda Joint Managing Director

O K Balraj Exe. VP & Group Chief Financial Officer

P S Pritam Director

Rajan Nanda Chairman and Managing director

S A Dave Director

S C Bhargava Director

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S Sridhar Chief Executive Officer
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1.6 Subsidiaries

Escorts Asset Management Ltd.
Escorts Automotive Ltd.
Escorts Agri-Machinery
Escorts Class Ltd.
Escorts Construction Equipment Ltd.
Escorts Heart Institute and Research Centre Ltd
Escorts Hospital and Research Centre Ltd.
Escorts Securities Ltd.
Escorts Telecommunication Ltd.
Esconet Services ltd.
Cellnext Solutions Pvt. Ltd.
I Serve India Solutions Pvt. Ltd.
Escosoft Technologies Ltd.
Escosoft Technologies (USA) Ltd.
Escosoft Technologies (UK) Pvt. Ltd.
Escosoft Singapore Pvt. Ltd.
E-Soft (Mauritius) Holdings Ltd.
Escotel Mobile Communication Ltd.
Escotel Telecommunication Ltd.












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Chapter -2

Agri machinery group

Introduction

Agri machinery group is the part of Escorts Ltd. In 1960, parent
company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture
into tractors. 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.

1.1Features of AMG

Escorts - AMG has Tractor manufacturing capacity of 72000 / annum which is the
highest in Asia at one location. Its manufacturing operations are divided in Four
plants as-

KMC
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
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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.

1.2 Turn Over

Present Turn over US$ 30 million.
Presently Production 72,000 tractors per annum.
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.













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1.3 Product




Table 2.1 Product

Product Brand
Escort E-325 Josh, E-335, MPT
JAWAN
Tractors
Hero, Champion, FT-40,
Farmtrac FT-45, FT-50, FT-60, FT-
70

PT 425, PT434, PT-439,

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Powertrac PT- 445, PT-4455


Crop solution Rotavator FT Hero, FT Champion

Laser leveler
Farmtrac 60 ,Farmtrac
65
MB Plough
Combrine Harvester FT 65, FT70
Egines Escorts G15, G20, G25, G30
Lubricants Farmtrac Gear oil, FT15W40

Transmission Oil,
Engine
oil
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1.4 Awards

a). Green tech Environment Excellence Award-2011-Knowledge
Management Centre (KMC) has bagged the Gold Category award in Engineering
Sector instituted by Green tech Foundation, Delhi for outstanding performance in

Environment Management

b). Escorts Agri Machinery (EAM) wins accolades at INSSAN-Employees
of EAM participated in various competitions organised by the Indian National
Suggestion Scheme Association New Delhi (INSSAN) at ESSEX farms,
Convention Centre, New Delhi on 3rd and 4th June 2011. INSSAN is a platform
to recognise the value of employees for their intelligence, experience, attitude
and feelings.

c). Escorts won Flower Festival Awards 2011 -organised by Haryana
Urban Development Authority.

d). Recognition of Escorts R&D Centre renewed for next five years i.e. up to
31st March 2016 based on R&D Projects under taken during last three years.

e). Company was the First Winner in Solid Model Contest 2011- this award
is about the focus on 3D imaging and predictive analysis to reduce the
number of physical prototype to save time, cost and energy consumption



1.5 Assembly of Engine and Clutch Mechanism

First there is clutch assembly. Single clutch organic coil type
clutch are fitted. Before the engine assembly there is assembly of various other
accessories such as Foot board, battery clamp and other links such as accelerator
pedal link, clutch link, brake link etc.

Engine from sub assembly are assembled to the main line. A four stoke 3 cylinder
diesel engine first assembled at the engine sub assembly.

The various links and mechanism between the engine and the gear box is fastened
together and the whole integral unit is checked for its complete accessories etc. In
all the above stages of assembly, the skilled workers are used to accomplish all the
stages of assembly. But they are also held by the pneumatic bolt guns and the over
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head automatic conveyors and the alarm conveyor etc to make their job easy.







Chapter-5


Steady of Cylinder Block Machining



Introduction

Cylinder block of four stroke four cylinder diesel engine is done after
casting. A cast cylinder block is comes from vendor. Machining of cylinder block
is done at 10 different machines. E4.286- It is the machining line of cylinder block
In this line 4 stroke engine cylinder block is machined. The total displacement of
the engine is 2860 cc.

5.1BSM 01- Block straight milling This operation perform in duplex
milling machine. It has two rotating cutting rotor
























Cylinder block
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Target- To have a rough cutting on sump phase and head
face. Depth of cut is 1.5 mm on each face. So cutting about 3
mm

Procedure- Locate the component from party dowel. Party dowel is used to
clamping the job. Party dowel is given by the party (supplier) which gives casting
to the company.

It rest on TCS (Tappet cover side) and clamp on NPS (Name plate side). This will
help in keeping job in correct position.

Rotation of cutter was clockwise when view from back side of
spindle. Separate motor for compressor, oil/water are used.

Feeds are automatic. Operator need to place the job and remove it.

Use the pully crain to lift the object. 6 buttons are provide in the lifter( Up, Down,
North, South, East, west).Now roller are provide to tilting the objects. This is done
by chain mechanism.
Now in order to remove chips and other waste like dust, compressed air is used.

Height of the cylinder block (i.e. distance between sump and head face ) is =
411.50.2 mm
Sump face width is equal to 1210.2 mm.
Time gear side to bell housing side is equal to 431.50.2 mm




5.2Machine-2

Mazak horizontal centre NEXUS 8800 II- In this machine mazatrol software is
used. There is continuous supply of machine (oil and water) to work as coolant and
cleaner.CNC machine here is used for Various operation on head and sump face
and cap sheet (finishing, drilling, counter drill, and tapping).

Procedure- Locate from party dowel and clamp.

Party dowel TCS (Tappet cover side)
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Clamp-NPS (Name plate side)

Setup-1

Head face- On the head face there are 18 holes (with tapping) are produced for
tightening the cylinder head. After that there is 9 more hole produce for the water
passage. These holes are drilled only. One more hole produce for oil passage.

Dimensions

For tightening of cylinder head 18 holes drilled of 10.5 mm

And counter drilled of 12.5 M




For water passage



For oil passing

One through hole of 7 mm




Sump Face-On the sump face there are two more dowel are created for further
machining process.

Dimensions 13H7

On sump face there are 14 more holes are produce.

Dimensions- drill of 8.5 mm
tapping of M101.5
And then two small dowels are created of 5
One more hole produce of 18.5 and tapped of M201.5
One dowel of 16H8 produced.


4 holes drilled of 10 mm
5 holes drilled of 6 mm
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Set up-2

With the help of manufactured dowel fixed sump face and perform on the
NPS, TGS, BHS, TCS.

Time gear side-On this face there is 2 holes drilled and one dowel machined.


Table 5.1 Hole dimensions



Side Size
TGS 6.8 drill M81.25 Tapping

18 drill M202 Tapping
16H8 dowel
TCS 2 holes 8.5 drilled M101.6 Tapping
3 bore 36

NPS 16.5 M181.5 Tapped
16.5 M183/4 Tapped
16.5 M181/4 Tapped
16.5 M181/8 Tapped

9 M101
BHS 12.5 M141.5
10.2 M121.75

5.3Machine-3


HMC-25 -This machine programmed with FANUC CODE. There are two types of
fixtures .Here we use mechanical rather than hydraulic. To mechanically these fixtures
we use close wise.

Use crain to hold the job and place on fixture with dowel on sump face. Now put close
wise and tighten the screw. We use brake (hydraulic) pedal in order to start /stop. After
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this rotation of fixture is done and now door were closed and change pallet and start the
program.

This is the special type of machine. On this machine we can perform all the
operations that are done earlier And this machine check the tool life also. This
gives OEE (Overall equipment efficiency) of the tool.

On this machine we perform oil glaring. This is done from crank to cam at 29
degree and from crank to idler at 18 degree. Oil gallery from crank to cam is longer
than crank to idler.

For change the pallet we use this program.



MOI M60 EOB Insert






Cycle start






Alternative of this machine are BD03 (block drill) and GBD01 (gear
block drill-gear box department)- In this machine drilling is done with the help of
radial drilling machine. These drilling machine two fixtures of 29 degree and 18 degree
are made so that drill can be done in straight manner.



5.4Machine-4


BSM12 (Block straight milling) - on this machine milling and notching is done at one
of the side used as a stopper for bushes. On this machine cutter have 10 side mill and
5 end mill.



5.5Machine -5
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BNR04 (Block Nut turner) -For main bearing cap bolt tightening first already
finished caps are put on the web and mechanically tightened using BNR.


5.6Machine -6

Now block again comes on the HMC25 (horizontal milling centre) for
crank, cam and idler boring. Here semi finishing is done. First rough boring is done
and there after semi finished boring is done. And thereafter it goes to vertical milling
centre.

5.7Machine -7

VMC26 (vertical milling centre milling centre) At VMC26 tappet boring is done.

Here it create 4 holes of 25 mm
dimensions




Also along these tappets are created 4 cams working. At this stage
checking of all dimensions are done hare. For checking all dimension they use ring
gauge, Bore dial gauge, Go not go plug are used.




5.8Machine -8

BSB14 Block straight boring -2 way boring. Here boring of crank,
cam and idler is being finished. Boring is done from both end since it is two way. In
this machine boring of crank/cam is done from one side and boring of idler from
another side.

5.9Machine-9

BWT4 (Block washing machine) - This is a washing machine with both type
of block air and block water cleaning. And final inspection is done over here.
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5.10Machine-10

BBP (block bush pressing) -For this purpose BEMCO hydraulic
press is used. This is used to put bush inside the cam hole. Capacity -25 kW.
Chapter-7

Conclusion





Summer training in Escorts Ltd. really helped me to familiarize myself to the
practical knowledge of industrial production and processes. T h e w h o l e training
period was very interesting, instructive and challenging. Through this training I was
able to gain new insights and more comprehensive understanding about the real
industry working condition and practice.

I got the idea of working of automatic CNC machines, Testing techniques of Diesel
engine, tractors and different processes used in machining of cylinder block and
Assembly plant. All of this valuable experience and knowledge that I have gained were
not only acquired through the direct involvement in task given but also through other
aspect of the training such as work observation, interaction with operators, supervisor
and other peoples involved in the process.

In assembly plant I saw how tractor are assembled. I get knowledge about different-
different sub assemblies of tractor assembly plant. Differential sub assembly,
transmission sub assembly, transmission testing, paint of body and different sub
stations.

It was a good idea and good chance to expose to the work environment that we will
have to face and practice after we graduate. As a result of the training now I am more
confident to enter the employment world and build my future career.





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References




1. http://euler9.tripod.com/bolt-database/22.html
2. http://www.escortsagri.com/
3. http://www.standardsbis.in/Gemini/search/BasicSearch.action?sear
chValue=hexagonhead bolts#
4. http://www.boltscience.com/pages/quality.htm
5. http://www.boltscience.com/pages/nutorbolttightening.htm
6. Introduction to Design Behavior of Bolted Joint by John H.
Bickford.
7. http://www.scribd.com/doc/51438283/1364-1
8. Material given to me by the company


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