TRAINING REPORT

OF SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN AT SWARAJ ENGINES LIMITED

Mahindra and Mahindra

IN Industrial Engineering
ON SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE OF BACHELORS OF TECHNOLOGY IN MECHANICAL ENGINEERING

Under the Guidance of: Name: Designation:Asst. Manager Department: I E

Submitted By: Name: College Roll No.: University Roll No.:

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ACKNOWLEDGEMENT
I hereby take this opportunity to thank those people who helped in successful completion of my training. This training gave me an opportunity to learn a lot of new things and meet great people who shall be held in great esteem. Firstly I would like to express deep gratitude & indebtedness to Mr.SANJAY BATRA, under whose supervision and hard-work I successfully completed my training at SWARAJ ENGINES LIMITED. He consistently helped and guided me in achieving the prime objective of my training. I also thank the teachers of the mechanical department of my college who consistently helped me. Last but not the least; I would like to thank the staff and work force of S.E.L who always gave their full co-operation in helping us to understand what we asked for.

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PREFACE
Training is an investment and hence should be able to get due returns in terms of better quality of workmen and Engineering for future. SWARAJ ENGINES LIMITED, M&M. today is one of the major Tractor Producer Industry, giving their best performing machines to their customers. As concerned with my Industrial training it is of my best opportunity during my Engineering to learn many things about the Automobile Industry through this Industry. During my training I got the opportunity to learn things that would pay to me in my near future. I pay thanks to the training faculty of our college and to staff and operators of SWARAJ ENGINES LIMITED for their co-operation during my Industrial Training.

Contents
Company profile 5-10

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Introduction to IE department Work done by the IE dept Types of Engines Manufacturing In SEL Components being machined Machine used in machine shop Operation being done Machine process of various components Crankcase Cylinder Head Gear Casing Cylinder Block

11 12 13-15 16 17 18 19 20-25 26-31 32-34 35-38 39 40-51 52-57 58-60 61-63 64-65 66

Project undertaken Process sheets SPC on sunkap machine Tool Life Time study

Layout

Bibliography

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COMPANY PROFILE

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INDUSTRY BACKGROUND
The Indian tractor industries as it now is a major segment of its engineering industry. However till 1947, Indian firms assembling semi knocked down (SKD) kits in collaboration with foreign manufactures met the tractor requirement of the country largely through imports and partly. Though the first tractor company was set up in India 1960, but the growth in real terms started from 1974, when the government banned the import of the tractors. Today India is the largest tractor producing and consuming country. In an effort to reduce imports and develop indigenous technology, the government, permitted setting up of the major manufacturing companies.

1. EICHER GOOD EARTH 2. TAFE 3. INTERNATIONAL TRACTORS 4. ESCORT TRACTORS 5. FORD TRACTORS 6. HMT 7. PUNJAB TRACTORS 8. KIRLOSKAR

1960 1964 1965 1966 1971 1973 1974 1974

PTL CAME INTO BEING

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Keeping in mind Punjab agrarian economy it was decided by Punjab Government to encourage the growth of industries with complements Punjabs agriculture growth. The task was entrusted to P.S.I.D.C. and with dual objective of industrial and agriculture growth, PTL was established on 27th JUNE 1974.

INTRODUCTION TO SWARAJ GROUP

Swaraj group came into existence with the establishment of Punjab Tractors Limited on 27th June 1974. The company was Indias first large scale based on totally indigenous design & technology, was promoted by Punjab State Industrial Development Corporation (PSIDC) with the help of Govt. of India & Public financial Institutions.

MAJOR COLLABORATIONS OF SWARAJ GROUPS

Swaraj group has entered into technical and financial collaborations with various national and international companies. The maximum share holder of swaraj is now Mahindra and Mahindra. Swaraj Mazda Limited was set with technical and financial collaborations with Mazda Motors corporation of Japan. Technical collaboration was entered into Komatsu Forklift Company of Japan for manufacturing fork lifters at swaraj combine Division. Swaraj Engines Limited was set up in technical and financial collaboration with kirloskar Oil Engines Limited, pune for Manufacturing diesel engines.

VARIOUS DIVISIONS OF SWARAJ GROUPS

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SWARAJ consists of six divisions:

1. Swaraj Tractors Division. 2. Swaraj Mazda Limited. 3. Swaraj Automotive Limited. 4. Swaraj Engines Limited. 5. Swaraj Foundry Limited. 6. Swaraj Combine Division.

1. SWARAJ TRACTORS DIVISIONS

It is located in phase IV, SAS Nagar. It started with an annual capacity of 5000 tractors with capital of Rs. 37 million. In 1974 it went into commercial production with swaraj 724 a 26.5 BHP tractor as its first model. During its 22 years of production it has not only expanded its manufacturing capacity to more than 24000 tractors per annum but also added more products into its manufacturing range. Its product range includes the following:

2. SWARAJ MAZDA LIMITED

P.T.L entered into technical and financial collaboration with Mazda Motors Coporation, Japan in 1984 to set up another company by name Swaraj Mazda Limited (SML) for manufacturing LCVs with capital outlay of Rs. 30 Crores. It is situated near Ropar town in the state of Punjab. S.M.L. went into commercial production in the year in the state of Punjab S.M.L. went into commercial production in the year 1986, at present it is manufacturing T-3500 buses of 3.5 tonnes payload capacity.

3. SWARAJ COMBINES LIMITED

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PTL setup the swaraj combine division (SCD) near chapper cheri village located in Tehsil Kharar, district Ropar of Punjab state. It was set up with capital outlay of Rs. 2.6 crores to manufacture self propelled harvesters or combines. In 1985 it also brought out diesel fork lifters of 2 tonnes and 2.5 tonnes lifting capacity. Later on the company entered into technical collaboration with Komatsu fork lift company of Japan for manufacturing both the diesel and electronic fork lifters of capacity up to 10 tonnes. In April 1995, it has also started production of Swaraj 922 tractors.

4. SWARAJ AUTOMOTIVE LIMITED

Swaraj Automotive Limited situated at nabha, district Patiala of Punjab state. It was a sick unit before the Swaraj group over took it, and with constant of the new management is again on the path to success. It supplies tractor seat, mudguards, bonnets etc. to the tractor division and seat to Maruti Ltd.

5. SWARAJ ENGINE LIMITED

Keeping in view the need to meet various emissions norms SEL has produce emmison measurement equipment and various standards are stringently followed.

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DEPARTMENTS OF S.E.L.
INDUSTRIAL ENGINEERING MACHINE SHOP ASSEMBLY AND TESTING SHOP QUALITY SHOP MAINTENANCE SHOP TOOL ROOM STANDARD ROOM AND TOOL CRIB STORES

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INDUSTRIAL ENGINEERING
Industrial Engineering is the most important department in terms of production, planning, designing and optimization of methods governing the factory operations. It deals in utilization of resources i.e. manpower, machines, money etc. Hence it can be considered as the backbone of production industries. For a new industry I.E department plays an important role. Its main functions involve the planning of layouts of all the shops to get the maximum benefits of the available space, setting the time standards to perform particular job by micro motion study, implementing the company standards. All type of data collection and data analysis, setting the targets and try to achieve them etc. the other function of this department may involve selection of cutting tools machine tools, designing of jigs, fixtures and inspection of gauges etc.

In I.E there are following four sections:

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 Machine Shop Processing:

This section controls processing of all components in machine shop and make continues production and make C.N.C. machines program for new components and improving exiting programmes. The new machines are setup by this section and development of new comp. also done.

Assembly and Projects:

This section controls the assembly shop and testing lab of plant. And ensure assembly line goes smoothly and fulfill its targets. It also implements new study. projects in the plant for increasing production and convenience of workers or operators. It also done time study and work

Tool Control Cell:

It controls tool crib of plant and assures proper supply of tools to various machines and also store proper amount of tools for regular production of components. It also reworks or re sharp the damaged tools.

Tool Design Cell

This section designs new tools, jigs, fixtures etc. according to requirements of various departments. It also improves exiting fixtures to achieve greater accuracy.

TYPES OF ENGINES MANUFACTURING IN SEL

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The Plant Manufactures five types of engines, which engines are sent to the swaraj tractor division, S.A.S. NAGAR. One of these is a single cylinder engine exclusively designed R&D plant of Swaraj. Out of rest one is two cylinder and others three cylinder engines. All the engines are Euro-3 and SEL is planning for modifications to be introduced, so that its engines may be Euro-4 compatible. The specifications of these engines are:

1. S-15, Single Cylinder:

Engine Specifications:
Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System : S-15 ; Swaraj 24.5 S.A.E. SWARAJ 722 4 - Stroke, Direct Injection, Diesel Engine 120 X 126 mm 1425 cc 1900 rev/min Water Cooled

2. RV-2, Two Cylinder:

Engine Specifications:
Model : HP : RV-2 xm KIRLOSKAR 26.5 S.A.E.

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Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :

SWARAJ 724 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 110 mm 1728 cc 2000 rev/min Water Cooled

3. RV-3, Three Cylinder:

Engine Specifications:
Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System : RV-3 xm KIRLOSKAR 39 S.A.E. SWARAJ 735 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 110 mm 2592 cc 2000 rev/min Water Cooled.

4. RB-30, Three Cylinder:

Engine Specifications:
Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System : RB-30 xm KIRLOSKAR 48 S.A.E. SWARAJ 744 FE 4 - Stroke, Direct Injection, Diesel Engine 110 X 110 mm 3136 cc 2000 rev/min Water Cooled with Oil Cooler for engine oil.

5. RB-33, Three Cylinder:

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Engine Specifications: Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :

RB-33 xm KIRLOSKAR 55 S.A.E. SWARAJ 855 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 116 mm 3308 cc 2000 rev/min Water Cooled with Oil Cooler for engine oil.

COMPONENTS BEING MACHINED:

Following parts of Swaraj Engines:
Crank case. Cylinder head. Gear casing. Connecting rod

Following parts of Swaraj Mazda Limited:

Cylinder block. Cylinder head. Connecting rod. Case transmission.

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MACHINES USED IN MACHINE SHOP:

Vertical milling machine Horizontal milling machine Radial drilling machine Gang milling machine Rough boring machine Semi-finish boring machine Finish boring machine Honing machine Gun drilling machine Washing machine Rotary grinder
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 Rough milling machine XLO valve lapping machine Line boring machine

OPERATIONS BEING DONE:

Grinding Drilling Semi-finish boring Finish boring Tapping Milling Chamfering Reaming Lapping Washing Assembly

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 Honing Deburring

MACHINING PROCESS OF VARIOUS COMPONENTS:

CRANK CASE CYINDER HEAD GEAR CASING CYLINDER BLOCK SML CYLINDER BLOCK SML CYLINDER HEAD CONNECTING ROD

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CRANK-CASE:
Crankcase is the housing for accommodating crank shaft and cam shaft. In SWARAJ tractors, crank case is cast separately and attached to cylinder block. The bottom face of crank case walls is flanged to strengthen the casing and to provide a machined joint face for sump to be attached. Crank-shaft is supported in the crank case through a number of bearings called main bearings. The construction of the crank case has to be such as to provide very high rigidity because it must provide reactions for the heavy forces set up to gas pressure in the cylinders. The cylinder block is mounted above the crank case. At the top of the cylinder block is attached the cylinder head. Attached to crank case is sump, flywheel, gear casing, fuel filter, water separator etc. The material of crank case is cast iron because it has following advantages:1. Good foundry material

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2. High machinability 3. It does not warp under high temp. & pressure developed in cylinders 4. It is slightly porous nature as it retains better lubricant oil film 5. It does not wear too much 6. Sound damping properties 7. Low coefficient of thermal expansion 8. It is relatively cheap

MACHINING PROCESS OF CRANK CASE

The casting of crank case is brought in the machine shop from vendor and following operations are performed on following machines in sequence :-

1.

SUNKAP MACHINE :
This machine is first machine of crank-case line on this machine is used for milling of sump face, cap mtg. face, top face (RV2, RV3, RB30/RB33) of crank-case. Milling at all three faces is done simultaneously by three milling cutters.

2. VERTICAL MACHINING CENTRE (V.M.C.) :

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There are two machines used for same operation for increasing production rate. It is used for milling, drilling and boring operations on Sump face, Cap mating face, Fuel filter Separator mating face drilling

3.

DUPLEX MILLING MACHINE :

This machine is Special Purpose Machine (S.P.M.) which is used for rough milling of gear end side and flywheel end side. In this machine cutter came from both sides and milling both sides simultaneously.

4. GANG MILLING MACHINE :

This is again a special purpose machine used for gang or gap milling. The milling of sides of cap mounting face are done. It has eight face milling cutters.

5. RADIAL DRILLING MACHINE:

On this machine, tapping of 8 holes on cap mounting faces is done. Also tapping operation in holes on sump face is performed .After that dowels are pressed on cap mating face by dowel pressing tool.

6. ROUGH BORING MACHINE :

It is a S.P.M. made by Kirloskar. On this machine, rough boring of Cam bore, Crank bore, and IG (intermediate gear) bore is done. Here the

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boring tools enter from both sides i.e. gear end side (GES) and flywheel end side (FWS).

7. GUN DRINLLING MACHINE:

It is used for drilling a main oil gallery of 16.

8.

WASHING MACHINE:
After drilling main oil gallery, the washing of crank-case is done for removing chips etc from the gallery.

9. NOTCHING UNIT:
It is used for making a notch in crank bore in crank case. Notch is used for supporting bearing, which is used to avoid friction between cap face and crank shaft.

10. HORIZONTAL MACHINING CENTRE:

This machine is used for drilling and boring operations on gear side end and flywheel end side.

11. VERTICAL MACHINING CENTRE:

This machine is used for drilling, milling, boring of top face and liner boring of crank-case. Two machines are used for same operation.

12. INDEXOR (3 in No.):

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This machine is used for making various galleries, dipstick hole, oil pressure gauge hole etc.

13. OIL GALLARY WASHING MACHINE:

Washing is done first with air, then with coolant. After this studs are inserted in holes on cap mfg. face and caps are tightened with impact wrench.

14. SEMI FINISH BORING MACHINE :

As the name suggests, this machine is used for semi-finish boring of cam bore, crank bore and idler gear bore of crank-case. In this machine tool came from one side.

15. FINISH BORING MACHINE:

This machine is used for the finish or final boring of crank bore, cam bore and idler gear bore is done. After this operation these bores should have the final dimensions.

16. TAPPET BORING MACHINE:

This is VA-50 a V.M.C. machine made by COOPER. This machine is used for finish boring of tappet hole where push rods are fitted .

17. FINISH DUPLEX PAL MACHINE:

This machine is used for finish milling of gear end side and flywheel end side with two cutters on both sides.

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18. HORIZONTAL MACHINING CENTRE :

This machine is used for boring and reaming operation on Gear end side and flywheel end side of crank-case.

19. ALEX GRINDER:

This is rotary surface grinder used for grinding of two side caps. Caps are clamped with magnetic table.

20. GANPAT WASHING MACHINE:

This machine is used for final washing of crank-case with coolant to remove all chips or other particles present in crank-case holes etc.

21. BUSH PRESSING UNIT:

After final inspection a bush is pressed in cam bore on gear end side to avoid friction between cam shaft and cam bore during running of engine.

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CYLINDER HEAD
Cylinder head is attached to the top of the cylinder block by means of studs fixed to the block. The gaskets are used to provide a tight leak proof joint at the interface of the head and the block. The cylinder head forms a combustion chamfer above each cylinder. It also contains injector holes and cooling water jackets. Besides valve openings are provided in the head. Upon which is also mounted the complete value operation mechanism. In all the cylinder heads of swaraj engines, the inlet and exhaust manifolds are placed on different sides of the cylinder head, it is called offset cross-flow type. Detachable head type has many other advantages over the integral construction.

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1. From production point of view, the cylinder block casting with open bore for the detachable type head, is much more simplified. 2. Operations like de carbonizing and value grinding are simplified 3. The comp. ratio can be changed slightly by changing the thickness of gasket used between the block and the head. The material used for cylinder head is cast iron There are separate sets of pipes attached to the cylinder head which carry the air and the exhaust gases. These are called manifolds. The cylinder has the nozzle bore in which the injector is inserted. The function of injector is to inject the fuel in the cylinder in properly atomized from and in proper quality. The cylinder head apart from having the inlet and exhaust manifolds (attached to cylinder head) has a water outlet manifold. On the top of cylinder head, is mounted the rocker arm, rockers shaft, push rods, springs rocker cover etc. The cylinder head also contains the inlet and exhaust valves. There is a water jacket in the cylinder head for the circulation of cooling water. The lubrication oil for the lubrication of rocker assembly enters from Rocker supply hole. Where it enters through rocker supply hole where it enters through rocker supply pipe from crank-case. RV2 and RV3 have the same cylinder head while RB30 and RB33 have the same. The S-15 has completely different cylinder head.

MACHINING PROCESS OF CYLINDER HEAD

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Some of RV cylinder heads in finished state are brought from vendor while some in semi-finish state are brought and finished in cylinder heads of RB are brought from vendor in semi-finished state and finished in cylinder head section itself. The machining process of cylinder head is as follow:-

1.

CNC 600:

First operation of cylinder head is done on C.N.C. machine. It is used for facing of liner bore in the liner bore or liner boring, the liner resets.

2.

BENCH DRILL:

After liner boring chamfering on valve guide holes and counter in inlet valve guide is done on this machine.

3.

DUPLEX MACHINE:

After chamfering milling of inlet and exhaust face is done on DUPLEX MILLING MACHINE. The two pieces are clamped hydraulically and milling on two faces is done simultaneously with two cutters on both sides.

4.

BORING MACHINE (XLO):

After inlet and outlet face milling, boring of Valve guide and valve seat are done on boring machine. Two tools are used on each side for rough cutting and finish cutting.

5.

VMC-40:

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This machine is used for Valve guide and V. seat boring of RB cylinder head. And nozzle boring operation of both RB and RV cylinder heads are also done. In valve guides bore, the guides are inserted and guide the valve. In valve seat the valves rest.

6.

RADIAL DRILLING MACHINE:

After nozzle boring four sides drilling of cylinder head is done on radial drilling machine.

7. CHAMFERING UNIT:
Here chamfering on all holes is done. Which are drilled on cylinder head in previous set-ups.

8. FLEXIARM TAPPING MACHINE:

This machine is used for tapping of holes. Tapping of holes around inlet and outlet port, water outlet etc. Tapping in pipe hole for rocker supply. Tapping on top where studs are inserted for clamping rocker support.

9.

Chamfer, Tap Gallery Washing and Core plug filter: Press valve guides and valve Seat inserts:
1. Place cylinder head on press table resting on top side.

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2. Clean valve seat inserts bores and valve seats with clean cloth properly. 3. Put one inlet valve seat insert in the mandrill and press in the respective bore (not used now). 4. Respect sr. no. 03 for exhaust valve seat insert. 5. Reverse the clamp. 6. Fit snap rings in valve guides with the help of hammer and special tool. 7. Press valve guide in valve guide bore with the help of tool.

10. WATER GALLERY TESTING MACHINE:

After above operations water gallery is tested by passing pressed air from water exhaust while water inlet is closed by on arrangement and then dipped in coolant for checking any leakage in plugs or blow holes in valve holes.

11. VALVE SEAT LAPPING:

1. Apply lapping paste on valves periphery and insert in valve seats 2. Hold the valves by rubber lapper. 3. Start the machine and lap the valves 4. Stop machine and release the job 5. Clean the seats- Valves with cloth properly 6. Place the comp. with top side up on washing unit. 7. Clamp cylinder head and start machine cycle. 8. Tap 1-hole M 10 1.5 and 15 deep. 9. Rotate camp and place on fixture to bring inlet side on top.
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10. Tap 1-hole M 101.5 and 10 deep. 11. Feed the comp. in the washing booth 12. Remove the comp from booth after washing 13. Clean the comp with air Jet and cloth. 14. Alloy lockset on care plug holes 15. Fit case plugs in core holes by hammer and punch

12. PRESSURE TESTING MACHINE

1. Place and clamp are cylinder head on the unit. 2. Clamp cylinder head pneumatically and dip ass in tank 3. Start air and check for any air bubble. Lift the head and release the job pneumatically and kept cylinder Head on conveyor.
4. Drain out excess coolant clean with cloth and put rubber stamp with

CuSO4.

13. LEAKAGE TESTING AND FINAL ASSEMBLY:

1. Remove cylinder head from washing unit and clean residuals with clean and dry cloth as per shop practice. 2. Insert valves from bottom side and place cylinder head on base plate. 3. Place the cylinder head on table put valve cup in the valves from top side. 4. Place 2 no. of valve springs with the help of fixture on inlet valve. Side and exhaust valve side.

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5. Press cups along with springs with the help of fixture on inlet valve. Side and exhaust valve side. 6. Insert collets pairs to take the proper seat with valve cup. 7. Test for leakage on valve leakage testing machine at air pressure of 4 kg/cm2 8. Re-lap the seats is leakage appears The emery paste is used in lapping process which acts as a grinder and grinder both valve and valve seat.

14. FINAL INSPECTION:

After leakage test and final assembly, final inspection of cylinder head is done. In this inspection the tap of holes and valve seats and valve guides are inspected by a quality inspector and then pieces are moved to assembly shop.

GEAR CASING
As the name suggests, gear casing is the casing for gears. It encloses the crank shaft gear, cam shaft gear, idler gear, FIP driving gear, lubricating oil pump assembly. It has following faces. 1. covering face or oil filler body mating face 2. crank- case mounting face 3. sump mating face 4. lubricating oil filter mating face 5. Plate face 6. Water pump mounting face

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Covering face: On this face, timing setter, tension lever, and pulley for driving crankshaft are mounted. Crank case mounting face: It is a face which meets with the gear end face of crank case. Sump face: On this face, sump is mounted. On water mounting face, water pump is mounted in RV2&RV3. but in case of RB30&RB33, the water pump is mounted on cylinder block. On this face alternator bracket is mounted in RV2&RV3. But in case of RB30&RB33, it is mounted on cylinder block

MACHINING PROCESS OF GEAR CASING:

1. VMC-40:
This is a machine made by Kirloskar, on this machine, the operations on the crank case mounting face are done. There are two machines on which same operations are done on this face. Dowel holes accommodates dowel pins so that the gear casing can be easily supported during fitting as these pins gets fitted into dowel holes on the gear end side of crank- case 4 drilled holes of 5mm are around bearing hole. Here plate is mounted

FIRST SET UP:

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4 drilled holes of 8.4 around FIP mating hole. Here FIP is mounted. Through FIP mating hole the FIP shaft passes on which adapter flange is mounted. With this adapter flange, the FIP driving gear is tightened Bearing hole accommodates bearing. The extended portion of gear casing where the plate is mounted accommodates the gear. This gear transmits motion to the hydraulic pump which is used for operating the lift hydraulic pump.

SECOND SET UP:

set-up is also done on a V.M.C.-40 machine. On

this machine the following operations are done on the oil filler body mating face. Here also two machines are used for same operation. Oil seal hole accommodates the end of shaft where oil seal is mounted which prevents the oil to come out of gear casing. On this end of crank- shaft, the pulley for giving a drive to it is mounted.

3. HMC-500
Third set-up of gear casing is done on H.M.C. machine. This machine is used for operations done on lubricating oil mating face, sump face, plate face and top face are done . Operations done are drilling chamfering & tapping .

4 .FLEXIARM:
The tapping of all faces are done on this machine by clamping in fixture specially designed for this operation& also side drilling is done.

5. WASHING MACHINE:

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After oil gallery drilling washing of gear casing is done on washing machine with coolant. Washing is done to remove chips and other components from oil galleries and other drilled holes. After washing cleaning of gear casing is done with air jet and de burring of gear casing is done.

6. LEAKAGE TESTING AND INSPECTION:

After washing oil gallery leakage test is done. First gear casing is dipped in coolant and air passed through oil gallery. If bubbles appear then there is leakage in oil gallery otherwise there is leakage in gear casing. After this final inspection of gear casing is done and then send to assembly shop.

CYLINDER BLOCK
It is an very important part of engine .In it liner with piston & connect & connecting rod assembly is placed.

MACHINING PROCESS OF CYLINDER BLOCK:

1. FN2EV:
On this machine milling operation is done on top face.
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2. VA-50r & VMC 1200:

On this machine milling , drilling ,chamfering ,reaming & boring operations are done.

3. HMC:
On this machine milling , drilling ,boring & tapping operations are done.

4. WASHING MACHINE 5. LEAKAGE TESTING 6. FINAL INSPECTION

SML CYLINDER BLOCK

Machine No. 1: HMC-500 (Horizontal machining centre) (No. 1075)

SET UP 1: Finish milling alternator and cooler side using bottom as reference. SET UP 2: Rough milling top face, rough and finish milling sump face.

Generation of reference dowels, brg, cap mtg, dowels and holes.

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 Machine No. 2: HMC- 500 (No.1088)

Mtg. holes, drill holes for idler gear, finish bore for core plug holes and main oil gallery plug hole. Semi finish drilling on FWS and GES drilling for mtg. holes. Finish boring for core plug holes, drilling for mtg. holes, oil gallery holes and water jacket holes.

Machine No. 3: HMC No.- 500 (no. 1077)

Rough bore for cam and crank bore, drilling for mtg. holes. Rough bore for cam and crank bore, drilling for finish bore for core plug holes and blind plug bores.

Machine No. 4: COOPER Gang Milling (no. 814.01)

Gap milling and notching

Machine No. 5: WIDMA Gun Drilling

Drilling of lubrication oil gallery

Machine No. 6: Gallery Washing

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 Machine No. 7: Rough Liner Boring Machine (no. 838.01)

Rough boring of liner

Machine No. 8: HMC -500 (no. 1092)

Rough and finish milling of oil jet face, oil jet mtg. hole, oil jet hole, angular oil gallery hole, and tapper holes.

Machine No. 9: HMC- 500

Machine No. 10: VMC -1200

Generation of dowel holes for cylinder head, finishing of liner bore, counter bore, and pipe seal, water gallery holes and mtg. holes.

Machine No. 11: Radial Machining RM- 62

Tapping on sump face oil cooler face and alternator face. Tapping for mtg. holes on F.W.S. head mtg. face.

Machine No. 12: SUNNEN Honing Machine Machine No. 13: Washing Machine
oil gallery and water jacket housing.

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 Machine No. 14: Leak Checking

Machine No. 15: Inspection

Visual inspection using lamp light

Machine No. 16: Packing and Dispatch

PROJECTS
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UNDERTAKEN

Project no:1
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UPGRADATION/ AUDIT OF PROCESS SHEETS & S.O.PS

WHAT ARE PROCESS SHEETS?

Process sheets provide description about tools,cutting conditions about a particular machine. A process sheet provides us following information:-

1. It provides information about feed,RPM, and depth of cut for a particular operation. 2 .It provides about tools,adapters, insertsalong with there stock numbers.

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3. It also provides the sequence of operations to be performed on those particular machines. 4. It provides us information of machine to be used,machine number, component,standard tools,special tools etc.

Here are some of S.O.P. sheets which i have up graded or audited in AVL cyl head process:

Project no:2
SPC on sunkap machine(286.01)

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Statistical process control (SPC)

It is the application of statistical methods to the monitoring and control of a process to ensure that it operates at its full potential to produce conforming product. Under SPC, a process behaves predictably to produce as much conforming product as possible with the least possible waste.

HOW TO USE SPC

Statistical Process Control may be broadly broken down into three sets of activities: understanding the process; understanding the causes of variation; and elimination of the sources of special cause variation. Statistical Process Control may be broadly broken down into three sets of activities: understanding the process; understanding the causes of variation; and elimination of the sources of special cause variation.

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In understanding a process, the process is typically mapped out and the process is monitored using control charts. Control charts are used to identify variation that may be due to special causes, and to free the user from concern over variation due to common causes. This is a continuous, ongoing activity. When a process is stable and does not trigger any of the detection rules for a control chart, a process capability analysis may also be performed to predict the ability of the current process to produce conforming (i.e. within specification) product in the future. When excessive variation is identified by the control chart detection rules, or the process capability is found lacking, additional effort is exerted to determine causes of that variance Once the causes of variation have been quantified, effort is spent in eliminating those causes that are both statistically and practically significant

SPC on Sunkap Duplex machine(286.01) Need : Variation in Size dimension 328+-0.1 and Dimension 15+- 0.1 from
component to component (maximum Variation 0.25mm)

PROCEDURE
1. Select the parameter (liner depth of cylinder block ) for which machine capability is to be calculated. 2. Give the SPC chart showing the upper scale tolerance limit & lower scale tolerance limit to the operator. 3. Operator is made to fill the readings on SPC chart at regular intervals.

ACTIVITY DONE
1.Component inspection (10 nos.) carried out for dim 328 at 4 points .

2.After the inspection the whole data is feeded For calculating the Machine capability which is called as CM. 3.The CM comes out to be 0.36.

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4. New Fixture for Sunkap was made for improving the CM of the sunkap machine. 5.Again the Component inspection (10 nos.) carried out for dim 328 at 4 points 6. Results are slightely better as the CM is increased to 1.37 7. Then the Component inspection (15 nos.) carried out for dim 328 at 4 points with different clamping pressure 8. Repeatbility Results are slightely better @ low clamping pressure

SUNKAP (286.01) M/C

Dim 3280.1 (on GES Avg. hole) Variation in different sub groups SUB GROUP NO.
Component Clamping Pressure Compone nt Clamping Pressure

40 Kg/CM SQ 1 2 3 4 5 6 7 8 0.08 0.21 0.3 0.05 0.08 0.06 0.1 0.02

35 Kg/CM SQ 0.03 0.02 0.08 0.06 0.04 0.14 0.12 0.05

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9 10 11 Repeatability (max.-min.) (Total sub groups)

0.08 0.13 0.04 0.28

0.1 0.06 0.02 0.12

Project no:3
Evaluate tool life of sunkap machine and Semi finish boring machine

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Tool life can be define as the length of time that a cutting tool can function properly before it begins to fail.

PROCEDURE:
Tool life of each tool used in sunkap & finish boring machine is calculated by making list of each tool that is used on these machines to make the required component.

Tool list of each tool is provided on each machine & operator is asked to fill the date & time of tool change.

After the data is collected about the date and time of tool change the next step is to fill the data into the table for calculating the tool life of sunkap & finish boring machine.

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Here are some table which i have up made for calculating the tool life .

Project no:4
Time study of RB CYLINDER BLOCK LEAK TEST.

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AIM: Time study of RB cylinder block leak testing ACTIVITY

1. Pick up the Component from Conveyor using tackle 2. Load the component on fixture of Leak testing unit 3. Remove the tackle from component & move hoist side 4. Locate the component from 2 locating pins 5. Put 3 clamps in position & ensure the location of rubber washer in push rod holes

6. Switch on the clamping lever upward to clamp the component hydro-

pneumatically. 7. Ensure the drain pipe in vertical position & fill the tank with coolant up to level marked
8. Observe the unit for 30 seconds for any air bubbles occurrence 9. After 30 seconds drain the coolant by operating the lever downward

10.Close the air inlet valve

11. Down the lever to declamp the component

12.Pick up the component from unit by inserting tackle & lifting up from unit
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13.Move the hoist to conveyors & unload the component on conveyor & draw back the tackle & move towards starting position

Project no:5
layout of machining line

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Aim: To make the layout of machining line, for the component

Which are machined in the plant, operation wise.

LAYOUT
From the beginning of the entrance of the industry it starts performing its job. The best optimum utilization of space .The most important and first task of IE in setting up a new industry or expanding the old industry in planning and make out the layout according to the process .At SEL , the expansion program has been carried out ,industrial dept.has played an important role in planning making the layout of various shops according to the requirements of the process & the target of making the new engines Layout on the machine floor for the foundation of machine fitting. Marking the final layout of the machine on the floor for the foundation of machine fitting.

Machines for which the marking is done are given below

1. RM 62 2. CD 40 3. SPM SML 4. SPARKONIX

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BIBLIOGRAPHY

1. Daily dairy. 2. Operators. 3. www.swarajenterprise.com

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