Escort Training Report On Cylinder Block
Escort Training Report On Cylinder Block
Escort Training Report On Cylinder Block
GREATER-NOIDA
ESCORTS LIMITED
Construction equipment
SUBMITED BY
SHARMA
NITESH KUMAR
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.
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.
CONTENTS
Certificate
Acknowledgement
II
Abstract
III
List of Abbreviation
Sr. No
Chapter name
Introduction
1.1
1.2
1.3
1.4
1.5
1.6
Agri-Machinery Group
2.1
Features of AMG
2.2
Turn over
2.3
products
2.4
Awards
conclusion
List of abbreviations
AMG-Agri machinery group
KMC-Knowledge Management centre
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.
1.2 Mission
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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.
Designation
CEO
Secretary
Hardeep Singh
Director
M G K Menon
Director
Nikhil Nanda
O K Balraj
P S Pritam
Rajan Nanda
S A Dave
S C Bhargava
12
S Sridhar
13
1.6 Subsidiaries
14
Chapter -2
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
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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.
16
1.3 Product
Brand
Escort
Tractors
Farmtrac
Crop solution
Egines
Lubricants
Powertrac
Rotavator
FT Hero, FT Champion
Laser leveler
MB Plough
Combrine Harvester
Escorts
Farmtrac Gear oil,
Transmission Oil,
Engine
oil
Farmtrac 60 ,Farmtrac
65
FT 65, FT70
G15, G20, G25, G30
FT15W40
17
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
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Chapter-5
Cylinder block
19
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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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
And counter drilled of
For water
4 holes drilled of
5 holes drilled of
10.5mm
12.5M
10 mm passage
6 mm
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.
21
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
TGS
TCS
NPS
BHS
Size
6.8 drill
M81.25 Tapping
18 drill
16H8 dowel
2 holes 8.5 drilled
3 bore 36
M202
16.5
16.5
16.5
16.5
M181.5
Tapped
M183/4 Tapped
M181/4 Tapped
M181/8 Tapped
9
12.5
10.2
M101
M141.5
M121.75
Tapping
M101.6 Tapping
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
this rotation of fixture is done and now door were closed and change pallet and start the
22
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
23
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
dimensions
25 mm
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.
5.10Machine-10
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Chapter-7
Conclusion
25
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
26