REPORT BASED ON IN-PLANT TRAINING IN
ENNORE, CHENNAI-57
BY SAIPARMESHRAJ.S &PRAVEEN.S SRM UNIVERSITY B.Tech MECHANICAL ENGINEERING FROM: 12-!-21" TO: 1"-!-21" 1
INTRODUCTION:
Th#$ %e'%( #$ )*$e+ ', ,'/e+0e (h*( I 0*#,e+ ', (he I, /*,( (%*#,#,0 I ,+e%('' ,+e%('' #, '% e//-'%0*,#3e+ e//-'%0*,#3e+ *,+ #,(e%e$(#,0 #,(e%e$(#,0 c'4*,. c'4*,. I h*5e %#((e, (he %e'%( ', (he 5*%#'$ $h'$ #, (he $*4e '%+e% *$ I 5#$#(e+. I h*5e %ec'%+e+ *$ 4ch *$ #,6'%4*(#', *,+ ,'/e+0e (h*( I c'//ec(e+ #, (h#$ 5#$#( c/e*%/ he%e. I h'e ' #// 6#,+ #( $*(#$6#,0. DAY - 2: FRAME ASSEMBLY (FA) & CHASSIS ASSEMBLY (CA)
D* 2 $(*%(e+ #(h *, #,(e%e$(#,0 *$$e4)/ ,#(. The 4'4e,( e 0'( #,(' (he $h' e e%e *)/e (' $ee (he c'4/e(e/ *$$e4)/e+ (%c 5
INTRODUCTION:
Th#$ %e'%( #$ )*$e+ ', ,'/e+0e (h*( I 0*#,e+ ', (he I, /*,( (%*#,#,0 I ,+e%('' ,+e%('' #, '% e//-'%0*,#3e+ e//-'%0*,#3e+ *,+ #,(e%e$(#,0 #,(e%e$(#,0 c'4*,. c'4*,. I h*5e %#((e, (he %e'%( ', (he 5*%#'$ $h'$ #, (he $*4e '%+e% *$ I 5#$#(e+. I h*5e %ec'%+e+ *$ 4ch *$ #,6'%4*(#', *,+ ,'/e+0e (h*( I c'//ec(e+ #, (h#$ 5#$#( c/e*%/ he%e. I h'e ' #// 6#,+ #( $*(#$6#,0. DAY - 2: FRAME ASSEMBLY (FA) & CHASSIS ASSEMBLY (CA)
D* 2 $(*%(e+ #(h *, #,(e%e$(#,0 *$$e4)/ ,#(. The 4'4e,( e 0'( #,(' (he $h' e e%e *)/e (' $ee (he c'4/e(e/ *$$e4)/e+ (%c 5
%e55#,0 6'% #($ (e$( +%#5e. 7e e%e ,*5#0*(e+ (' (he 6%*4e *$$e4)/ $' (h*( e c'/+ 0e( *, #+e* '6 h' 6%'4 +', (' (he e*%(h (he 5e% *$#%#,0 (%c #$ *$$e4)/e+. S' e 6#%$( +*$he+ #,(' (he 6%*4e *$$e4)/ ,#(. FRAME ASSEMBLY: ASSEMBLY:
Th#$ ,#( h*$ *%',+ 8 $(*0e$9 e*ch %'5#+e+ * $ec#*/ 6,c(#', (' /*. Le($ $ee *// (he $(*0e$ ',e ) ',e9 I.
II.
III.
FSM LOADING: LOADING: The *c%',4 FSM /e*+$ (' * +e6#,#(#', F#,#(e S(*(e M*ch#,e. The *%e )#/+#,0 ce//$ '6 * 6%*4e. The *%e /'*+e+ ', (he c',5e'% )e/( #(h ''+e, /'0$ 6'% 4',(#,0 6'% e*$ '%. Th#$ c',$#$($ '6 (' $e*%*(e 4e(*/ #ece$ c/*4e+ #(h h'/+#,0 +e5#ce$ /#e $;*%e /*(e$ 6'% 6%(he% 4',(#,0$. A6(e% A6(e% (he *%e $e( ', (he c',5e'% #( #$ $e,( (' (he ,e<( $(*0e. CROSS MEMBER FITMENT: FITMENT: C%'$$ 4e4)e%$ *%e (h'$e ='#,#,0 4e4)e%$ )e(ee, (' (' FSM$. FSM$. A)'( A)'( (h%ee c%'$$ c%'$$ 4e4)e%$ 4e4)e%$ *%e 6#((e+ he%e. The *%e %'5#+e+ (' c%e*(e (h%ee $e04e,($ h#ch *%e e,0#,e *,+ 0e*%)'< $e(9 6%',( *
IV.
SPRING BRACKETS FITMENT: The$e *%e $%#,0 )%*ce($ %'5#+e+ (' 4',( (he *
V. VI.
SPRING BRACKETS FITMENT: SPRING BRACKETS FITMENT: I, )'(h (he *)'5e $(*0e$ (he $*4e '% #$ h*,+/e+ )( #, $(*0e$ (' %e+ce )%+e,.
VII.
CAB MTG BKT FITMENT & SPEC MARKING: Th#$ $(*0e +'e$ * $ec#6#e+ 6,c(#',. I( %'5#+e$ c/*4$ 6'% 6#<#,0 (he *#% (*,$. The *%e %'5#+e+ #, > ,'$ *,+ #( #$ $)=ec(e+ (' %e;#%e4e,(. He%e (he *%e %'e%/ /*)e//e+ *6(e% (he *%e %'e%/ 6#((e+ #(h (he ?C@ $h*e+ c/*4$. The h'/e *$$e4)/e+ 6%*4e #$ ,' /*)e//e+ #(h c'/'%e+ ch*/$. N' (he 6%*4e #$ c'4/e(e/ +',e #(h *$$e4)/#,0.
VIII. IX.
FRAME UNLOADING: FRAME UNLOADING: He%e (he *$$e4)/e+ 6%*4e #$ ,/'*+e+ 6%'4 (he c',5e'% *,+ 4*+e %e*+ (' 4'5e #( (' (he ch*$$#$ *$$e4)/ $ec(#',. Th#$ '% #$ */$' +',e #, (' $(*0e$ )*$e+ ', (he '% /'*+. 7
CHASSIS ASSEMBLY:
Th#$ $ec(#', '6 *$$e4)/ #,c/+e$ (he *++#,0 '6 '%#,0 *%($ '6 * (%c #, 5*%#'$ $(*0e$. Th#$ *$$e4)/ *%e* h*$ *%',+ 1" $(*0e$. A6(e% e*ch $(*0e e c*, $ee (he (%c )e#,0 +e5e/'e+ $(*0e ) $(*0e. Le($ $ee (h'$e *$$e4)/ /e5e/ $(*0e$ ',e *6(e% (he '(he% #, '%+e% ,'. i.
FRAME LOADING: He%e ,'(h#,0 )( (he *$$e4)/e+ 6%*4e h#ch *$ (he e,+ %'+c( '6 (he $ec(#', ?6%*4e *$$e4)/@ #$ /'*+e+ ', (he c',5e'% )e/( '6 (he ch*$$#$ *$$e4)/ $ec(#',. Th#$ *c(#5#( #$ $*// e%6'%4e+ ) $#,0 c%*,e$.
ii.
FRONT AXLE MOUNTING: I,#(#*// )e6'%e 4',(#,0 (he 6%',( *
8
')$e%5e+ (h*( (h'$e $%#,0$ e%e ='#,e+ (' (he *
REAR AXLE MOUNTING: A$ #, (he c*$e '6 6%',( *
iv.
AXLE TORQUING: Th#$ $(*0e +'e$ (he =') '6 ('%;e#,0 #.e %'e% *+=$(4e,($ '6 (he *
v.
SILENCER MOUNTING: N' 4*ch#,e #$ 1 e66#c#e,(. S' #( #$ (he c*$e '6 e,0#,e$ (''. The $e/e$$ 0*$e$ %'+ce+ #,$#+e (he e,0#,e *%e e<e//e+ '( $#,0 (he e
(' %e+ce (he e4#$$#', %*(e '6 h*%46/ 0*$e$ *,+ */$' /*$ *, #4'%(*,( %'/e #, $',+ '6 (he (%c. vi.
CHASSIS TURNOVER: The 4',(#,0$ '6 5*%#'$ c'4',e,($ ', (he *$$e4)/e+ 6%*4e (#// ,' *$ +',e #, $#+e +', *. S' (he h'/e 4#+*$$e4)/e+ #ece $h'/+ )e (%,e+ '5e% 6'% (he /*ce4e,( '6 6%(he% %'+c($. Th#$ $#$ +',e $#,0 * ch*#,e+ //e #(h * c/'(h /#e 4*(e%#*/ 6'%4#,0 * )e/( *%',+ (he 6%*4e. I( #$ /#6(e+ *,+ (he ch*#, ', (he //e *%e *c(*(e+ he/#,0 (' (%, (he h'/e #ece +',$#+e .
vii.
FUEL TANK MOUNTING: Th#$ $(*0e #$ ,'(h#,0 )( he%e (he 6e/ (*,$ *,+ )*((e%#e$ *%e *((*che+ (' (he (%c 6%*4e. Nece$$*% c/*4$ *%e %'5#+e+ 6'% (he 4',(#,0 '6 6e/ (*,. A )*% /#e $(%c(%e #$ */$' %'5#+e+ 6'% (he #,$(*//*(#', '6 )*((e%#e$. O, ')$e%5*(#', e 6',+ '( (h*( (he )*((e%#e$ $e+ '5e% (he%e *%e c'44',/ AMARON *,+ E<#+e E<%e$$.
viii.
ENGINE MOUNTING: N' #( *$ (he (#4e 6'% 6#<#,0 (he he*%( '6 (he (%c. The e,0#,e #$ %e-*$$e4)/e+ #(h (he 0e*%)'< *,+ )%'0h( (' 4',( ', (he $*ce %'5#+e+ )e(ee, (he c%'$$ )e*4 4e4)e%$. The e,0#,e *$$e4)/ *$ ;#(e #,(e%e$(#,0 (' $ee *,+ #( h*+ 4*, #,(%#c*(e c',,ec(#',$ (' 4*e9 $' #( c*//e+ 6'% 4'%e 4*,'e%. The 6%',( *
*((*ch4e,($ e%e */$' e$(*)/#$he+ *$ $'', *$ (he e,0#,e *$$e4)/ *$ '5e%. ix. RADIATOR MOUNTING: Th#$ #$ (he (#4e 6'% (he #,$(*//*(#', '6 $/e4e,(*% c'4',e,($ '6 (he he*%(. The %*+#*('% #$ %e;#%e+ #, *// *$ec($ 6'% (he 5e% 0''+ e%6'%4*,ce '6 (he 5eh#c/e. I( *$ */$' %e*$$e4)/e+ *,+ *$ 4*+e %e*+ (' )e +#%ec(/ #,$(*//e+. x.
xi.
OIL FILLING: He%e (he 5*%#'$ (*,$ %'5#+e+ #,$#+e (he (%c *%e 6#//e+ #(h %e$ec(#5e 6/#+$ *,+ 6e/$. I, (h#$ $(*0e 5*%#'$ c',,ec(#',$ '6 (he$e (*,$ *%e */$' c/e*%/ e$(*)/#$he+. DRIVER UNIT:
N' (he 6%*4e #(h *// (he ,ece$$*% c'4',e,($ *%e %e*+. S' ,' e ,ee+ * %'e% /*ce 6'% (he +%#5e% (' c'46'%(*)/ $#( *,+ 'e%*(e (he (%c. The h'/e +%#5e% ,#( #$ *0*#, %e*$$e4)/e+ #, * +#66e%e,( $h' *,+ #$ )%'0h( 6'% +#%ec( #,$(*//*(#',. Th#$ #,$(*//*(#', ('' 4ch (#4e *,+ /*)'%. A// c*)/e$ e%e $e( 6'% 4'%e e/ec(%#c*/ c',,ec(#',$ (' )e 4*+e #, (he c'4#,0 $e04e,($.
xii.
ELECTRICALS: Th#$ #$ (he /*ce he%e *// (he #4'%(*,( e/ec(%#c*/ c',,ec(#',$ *%e e$(*)/#$he+. A// (he 5*%#'$ c*)/e$ h#ch e%e /e6( '( #, +#66e%e,( 11
$ec(#',$ '6 (he *$$e4)/ /#,e *%e *// %'e%/ 0#5e, *((*ch4e,($. Th#$ '% #$ 4*#,/ h*,+/e+ ) (%*#,e+ e/ec(%#c*/ '%e%$. xiii.
WHEEL MOUNTING: Th#$ $e04e,( #$ 6'% (he #,$(*//*(#', '6 hee/$ ', )'(h (he *
xiv.
WHEEL TORQUING: Th#$ $e04e,( #$ %e/ 4e*,( 6'% (he %'e% #,$(*//*(#', '6 (he %e6#((e+ hee/$ ', (he *
xv.
VEHICLE STARTING: I, (h#$ $e04e,( * (%*#,e+ +%#5e% c/#4)$ #,(' (he (%c (' $(*%( (he e,0#,e *,+ 0#5e /#6e (' (he (%c. The 5eh#c/e ',ce $(*%(e+ #$ (he, /e( #, ON $(*(e (#// #( #$ (e$( +%#5e,.
xvi.
OFF-TRACK: Th#$ #$ (he %e*/ (e$(#,0 '6 (he (%c ', (he %'*+$. T%*#,e+ +%#5e%$ (*e (he #,ch*%0e *,+ %e5 #, (he $(%ee($ '6 E,,'%e (' (e$( *,+ */$' e
DAY-3: SHOP VI Th#$ $h' +'e$ *c(#5#(#e$ /#e c/#,+e% )/'c$9 c*4 $h*6($ *,+ c/#,+e% he*+$. M'%e'5e% #( %'+ce$ c/#,+e% )/'c$ 6'% (' #,+$ '6 e,0#,e$9 ,*4e/ H *,+ Ne(,eN. Ne(,e e,0#,e c/#,+e% )/'c$ *%e 0#5e, * c'/'% c'+e '6 )/e *,+ H )/'c$ %e+. The 4'4e,( e $(ee+ #,(' (he $h' e e%e *)/e (' $ee (he Ne(,e )/'c$ )e#,0 'e%*(e+. The h'/e $e( *$ $'%( '6 6*$c#,*(#,0 $#,ce #( h*+ 5e% #,(e%*c(#5e e4/'ee$ *,+ * 0%e*( +e*/ '6 (ech$. H-CYLINDER BLOCK PROCESS:
He%e (he%e *%e 4*='%/ > 7'% Se((#,0 S(*(#',$ 7SS. F%'4 e*ch 7SS (he c/#,+e% )/'c$ e#(he% $(*%( (' 0e( 4*ch#,e+ '% %e*ch *6(e% ,+e%0'#,0 5*%#'$ %'ce$$e$. The%e *%e (' 4*='% '% $(*(#',$ he%e9 (he *%e ,*4e+ *$ 7SS- *,+ 7SS->. F#%$( /e($ $ee (he %'ce$$ 6/' '6 7SS-. The ,*4e '6 e*ch %'ce$$ #$ $e/6-e</*,*('%.
DRYING
7SS
& AIR
BLOWING
LINER
BORE GRADIN G
TAPPET REAMING
LINER HONIN
BORE WASHING
G
13
1#
BEARING CAP DISSASSEMBLY
HIGH PRESSRE IN"ECTION FLOOD WASHING
IP FACE WELSCH PLG PRES S
F!E & R!E WELSCH PLG PRESS
LINER BORE OILING
MANAL WELSC H PLG PRES S
OC FACE WELSCH PLG PRESS
GENERAL WASHING
FONDRY INSPECTION $ONE
CAM BSH PRESS
WATERWAYS LEA% TESTING
OIL PMP PERFORMANCE CHEC%
BORIN G
LINER COROSS AL
FINISHE D
BLOC%S
LINE R PRES S
PROTECTI E
COAT APPLYING
N' /e($ $ee *)'( 7SS-> %'ce$$ 6/':
CRAN % WSS-3 BORE DEBRRING
SEMI-
OIL PMP
FINISH
BOREBS H
LINER PRO"ECTION AND CHEC%ING
BLOC% NMBERING
FINISH LINE BORING
THRST FACING
NMBER MAR%ING
BEARING CAP
GALLERY
ASSEMBLY
LEA% TEST
OIL
ON BLOC%
& 'B( CAP
HIGH
BOSF
BOSF
BLOC% S
BLOC%
FROM
LOADING
STORE
PRESSR E WASHIN G
S
SPECIAL FEATURES:
1 CNC 4*ch#,e$ #(h *('4*(#c 0#+e+ 5eh#c/e 6'% /'*+#,0 *,+ ,/'*+#,0. 2 Ce,(%*/#3e+ c''/*,( & ch# h*,+/#,0 $$(e4. Fe #,(%#c*(e +e(*#/$ '6 %'ce$$e$ (*#,0 /*ce #, ?I,=ec(#', 6/''+ *$h %'ce$$@ *%e: * I+/e $(*(#', ) I,=ec(#', 6/''+ *$h c H#0h %e$$%e +e)%%#,0 + T' )((#,0 *,+ $%* *$h e 7'%#ece OG )((#,0 *,+ $%* *$h 6 I+/e $(*(#', 0 T%, '5e%
h I+/e $(*(#',. 16
NEPTUNE BLOCK PROCESS FLO:
N BLOC% LOADING
BEARING CAP ASSEMBLY) TIGHTEN & NMBER MAR%ING
SMP FACE OPERATION
BEARING
SEMI-FINISH
MACHINING
CAPS DISS-
OPERATION
ASSEMBLY
IN"ECTION FLOOD WASHING
LINE
PRESS
BORING
WELSCH
PLGS
INSERT
LINER TO
BORES
PRESSRE
TESTING &
PROTECTIE
FINISHED
OIL COAT
BLOC%
WATERWAYS LEA% TEST
17
DAY-!: SHOP-I
Th#$ $e04e,( '6 (he 6*c('% +e*/$ #(h (he 0e*%)'< c'4',e,($ %'+c(#',9 *$$e4)/ *,+ (e$(#,0 '6 (he *$$e4)/e+ 0e*%)'<. Le($ $ee (he %'ce$$ 6/' '6 e*ch c'4',e,( '6 (he 0e*%)'<. MAIN SHAFT "EARS: ROG H
HOBBIN
SHAPING
BLAN%
G
TOOTH
HEAT TREATMEN T
CHAMFERIN G
WASHING
BORE & TEETH
FACE
FINISHE D
WASHING GRINDING
GRINDIN
BLAN%
G
LAY SHAFT "EARS:
ROG H
BLAN%
HOBBING
TOOTH
CHAMFERIN G
18
WASHIN G
TEETH GRINDIN G
BORE GRINDING
HEAT
WASHIN G
TREATMENT
FINISH
BLAN%
"EAR BO# CASIN":
ROGH
BLAN%
FINISH MACHINING
DEBRRING
BLAN%
LAY SHAFT:
ROGH
BLAN%
WASHING
HOBBING
HEAT TREATMEN T
FINIS H BLAN %
TEETH
BORE
GRINDING
GRINDING
OD
GRINDING
19
MAIN SHAFT:
ROGH SHAPING
BLAN%
THREAD GRINDING & FINISIH
SPER FINSIH
HOBBING
OD
GRINDING
WASHING
HEAT TREATMENT
INPUT SHAFT:
ROGH SHAPING
BLAN%
TEETH GRINDING
HOBBING
BORE GRINDING
WASHING
OD
HEAT TREATME
GRINDING
& FINISH
NT
SYNCHRO PARTS: ROGH
BLAN%
BROACHING
HOBBING
WASHING
20
FINISH GRINDING BLAN%
HEAT TREATMEN T
The $' c*//e+ $,ch%' *%($ #,c/+e: R#,0 S/ee 5e H) C',e DAY $ %: SHOP $ ! O, 4 +*-1 I 5#$#(e+ (he $h'-. He%e I 6',+ '( (h*( (h#$ $h' #$ $'/6// *//'c*(e+ ',/ 6'% (he *$$e4)/ '6 6%',( *,+ %e*% *
A 6e *
F%',( *
TRFR )e*%#,0 F%',( h)
Re*% *
I( *$ $%%#$#,0 (' ,'(e (h*( *// (he$e c'4',e,($ *%e c'4/e(e/ $/#e+ ) ?M*h#,+%*@ *,'(he% I,+#*, '%#0#, 0#*,(. I( *$ #4%e$$#5e (' $ee )'(h I,+#*, c'4*,#e$ 0%'#,0 h*,+ #, h*,+ e,c'%*0#,0 e*ch '(he%. The h'/e *c(#5#( 0'#,0 ', #, (h#$ $h' c*, )e e</*#,e+ $#,0 (h%ee c*(e0'%#e$. The *%e9 1 A#LE STORE: Th#$ #$ /*ce he%e (he /'*+ (%c$ +e/#5e% (he *
He%e (he *$$e4)/ '6 6%',( *
hee/$. The 6%',( *
FRONT ALE BEAM
FRONT BRAE DRUM
ASSEMBLED FRONT ALE
& SUPPLEMENTAR Y ATTACHMENTS BOOSTERS
TRFR BEARING
FRONT ALE HUB
S/e4e,(*% *((*ch4e,($ #,c/+e $4*// e( ,c'4%'4#$#,0 6'% *
7he%e*$ *,'(he% *
REAR ALE BEAM
LIVE & DUMMY
ASSEMBLED REAR ALE
REAR BRAE DRUM
SUPPLEMENTARY ATTACHMENTS
TRFR BEARING
REAR ALE HUB
The $#0,#6#c*,( +#66e%e,ce )e(ee, 6%',( *,+ %e*% *
CONCLUSION:
Th#$ I,-P/*,( T%*#,#,0 *$ #,+ee+ * 4e%e he*5e,/ e<e%#e,ce. A// h0e (%c$ %e55#,0 ', (he %'*+$ #, *,+ '( (he /*,(9 '6(e, 4'5e4e,( '6 /'*+ 4'5#,0 c*%$9 $',+$ '6 /*%0e *%($ '6 (%c )e#,0 %'+ce+9 *$$e4)/e+ *,+ (e$(e+9 he/6/ e4/'ee$ *,+ $(%#c(
$ec%#(#e$. The ,'/e+0e (h*( e 0*#,e+ #$ )',(#6/ *,+ e *c(*// $* #, 6%',( '6 $ (he 4e%e */#c*(#', '6 h*( e $(+ '( (he%e #, '% c'//e0e c*4$. 7e *%e (%/ #,+e)(e+ (' G.*%(h#e*, h' 0'( $ (h#$ ',+e%6/ ''%(,#(.
21
SFSHF"G%HL)*"O*%!L S+S+S +
CC AC AC ACD 22