INPLANT TRAINING AT ASHOK LEYLAND TRANING PERIOD: PERIOD: 19-04-2011 TO 2604-2011
MURRUGAPPA COLLEGE •
R. Kavitha anjali
•
S. Lalitha
•
K. Naveen kumar
•
G. Parthiban
POLYTECHNIC
INPLAN INPLANT T TR TRAIN AINING ING SCHEDULE 19-04-2011 -
ENGINE ASSEMBLY
20-04-2011 -
MACHINE SHOP III
21-04-2011 - MACHINE SHOP IV 23-04-2011 – CHASIS ASSEMBLY 26-04-2011 – MACHINE SHOP II
ABSTRACT This is a report on in-plant training carried out at ashok Leyland limited, ennore plant during 19-04-2011 to 26-042011. This report covers the important manufacturing process carried out at the industry. This report includes the aspects of production carried out at the sections like chasis assembly section, shop II, shop III, shop IV and engine assembly section. At the chasis assembly section, the chasis goes through various stages in which different components were attached to metal frame. In total there were 19 stages through which the frame passes through to become the skeletal function body of mobile function body of the automobile which can be a bus, track, or other such goods carrier. At the shop II various components of engine were produced. At
the
engine
assembly
section
the
various
components being manufactured in shop II were assembled
to form the engine and the assembled put to test for any correction required. At the shop III, metal plates were assembled to form the complete frame. The frame passes through 10 steps in which various cross railings and mounts were fitted to frame to form the complete chasis. At the shop IV, the assembly of rear and front axles were carried out.
Acknowledgement First and foremost, we thank the management of ashok Leyland for following us to carry out our in plant training in their esteemed concern.
We
also
thank
various
employees of the concern who spared their time answering our questions in spite of their busy schedule. Last but not the least we thank the almighty for keeping us in good health and for giving us this wonderful opportunity.
INTRODUCTION: Ashok Leyland (NSE: ASHOKLEY, BSE: 500477) is a commercial vehicle manufacturing company based in Chennai, India. Founded in 1948, the company is one of India's leading manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles. Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment with a market share of 28% (2007–08). With passenger transportation options
ranging from 19 sweaters to 80 sweaters, Ashok Leyland is a market leader in the bus segment. The company claims to carry over 60 million passengers a day, more people than the entire Indian rail network. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. However Ashok Leyland has presence in the entire truck range starting from 7.5 tons to 49 tons. The joint venture announced with Nissan Motors of Japan would improve its presence in the Light Commercial Vehicle (LCV) segment (<7.5 tons). The origin of Ashok Leyland can be traced to the urge for self-reliance, felt by independent India. Pundit Jawaharlal Nehru, India’s first Prime Minister, persuaded Mr. Raghunandan Saran, an industrialist, to enter automotive manufacture. The company was established in 1948
as Ashok Motors, to assemble Austin cars. The
company’s destiny and name changed soon with equity participation by British Leyland and Ashok Leyland commenced manufacture of commercial vehicles in 1955. Today the company is the flagship of the Hinduja Group, a British-based and
Indian
originated
transnational
conglomerate.Early
products included the Leyland Comet bus which was a passanger body built on a truck chassis, sold in large numbers to many operators, including Hyderabad Road Transport, Ahmedabad Municipality, Travancore State Transport, Bombay State Transport and Delhi Road Transport Authority. By 1963,
the Comet was operated by every State Transport Undertaking in India, and over 8,000 were in service. The Comet was soon joined in production by a version of the Leyland Tiger . In 1968, production of the Leyland Titan ceased in Britain, but was restarted by Ashok Leyland in India. The Titan PD3 chassis was modified, and a five speed heavy duty constant-mesh gearbox utilized, together with the Ashok Leyland version of the
O.680
engine.
The
Ashok
Leyland
Titan
was
very
successful, and continued in production for many years.Over the years, Ashok Leyland vehicles have built a reputation for reliability and ruggedness. This was mainly due to the product design legacy carried over from British Leyland. And this is the report of In plant training done in this well reputed organization for period of two weeks.
ENGINE ASSEMBLY : DATE OF TRAINING: STAGE 1: CAM BEARING
19-04-2011
Crank case SWR/plate/EII NO is brought to the engine assembly, here cam bearings are fixed to the crank case of the engine. STAGE 2: CAM SHAFT
Cam shaft types E0/EI/EII NO are fixed in appropriate place in the crankcase. STAGE 3: CRANK SHAFT
Crank shaft, make BM/GB is fixed at base of crank case like passing thru hole. STAGE 4:
M-14 STUDS are fixed at the holes on the crankcase. STAGE 5:
In this stage 1st and 6 th piston is kept at the top dead centre and timing gears are fixed to side of the engine for the firing order. STAGE 6: CAM GEAR
Cam gears are fixed on the crankcase to operate the cam shafts in order to operate the valves.
STAGE 7:
FLYWHEEL housing is fixed on the crankcase of the engine . STAGE 8:
The flywheel is placed on the housing and 90torques is applied to it. The flywheel housing consists of seal housing, flange and flywheel. STAGE 9: OIL PUMP
Oil pump is fixed on the top of the crankcase to circulate the oil to the various parts of the engine. STAGE 10: PISTON
The readily made piston is fixed inside bore of the crankcase and connected to the crankshaft. Before that, piston rings of three types, two compression rings and an oil ring are fixed on the piston. STAGE 11: CONROD BOLT
Conrod bolt
is fixed to connect the piston with the crank
shaft. STAGE 12: IDILING GEAR
It’s fixed on the spindle which controls the rotations of cam gear, crank gear and compressor gear.
STAGE 13: CYLINDER HEAD
Cylinder head is fixed to the top of the crankcase to which rocker arm with valves are fixed. STAGE 14: OIL SUMP
Oil pump is fixed at the bottom of the crankcase with adhesive (RTV) paste. STAGE 15: ROCKER
Rocker assembly is fixed to the cylinder head. STAGE 16: AIR COMPRESSOR
AIR COMPRESSOR is fixed to the crank case. STAGE 17: FUEL INJECTION PUMP
Fuel pump is fixed to LTC/EII/EI types of engines. STAGE 18: VALVE COVER STAGE 19: OIL COOLER STAGE 20: INJECTOR PIPE AND INLET MANI FOLD is fitted . STAGE 21: SIDE COVER STAGE 22: WATER PUMP STAGE 23: STARTER MOTOR STAGE 24: EXHAUST MANIFOLD
STAGE 25: TURBO CHARGER STAGE 26: EII FTMENTS STAGE 27: Fully assembled engine is taken to the testing
area to be tested for is performance.
MACHINE SHOP III: DATE OF TRAINING:
20-04-2011
The chassis of the vehicles’s first step starts from here at this shop-3. The frames of the vehicles are fixed together to be sent to the chassis assembly. The skids are mounted on the conveyor belt and frame is placed on the skids. And frame MTG on which engine is mounted is fixed across the two frames. On the rear end of the frame BKTS both sides are aligned with taper pin. Fit and tight FSR and BKTS on both sides with dummy bolts. Tilt both the FSMS to 90 degree by turning tackle and insert clamps. Tight and apply torque to engine MTG flinches and M12 with bolts. Correspondingly
in
every
stage
each
workers
tight
appropriate bolt to the frame before taken to chassis assembly make it a complete frame.
MACHINE SHOP IV: DATE OF TRAINING:
21-04-2011
This shop-4 is divided into two departments where the front and rear axles of the vehicles are assembled with leaf springs, brake drums before being attached to the main frame of the vehicle.
FRONT AXLE ASSEMBLY: STAGE 1: Axle beam is loaded on the conveyor belt. STAGE 2: Number is punched on the axle beam. STAGE 3: Axle arm is fitted on the beam for steering. STAGE 4: Steering rod is fitted. It is right end of the axle according to Indian STDs.
STAGE 5: Tracking rod is fitted. It is used for the alignment of the wheel. It helps the left side of the tyre to turn along with the right side wheel. STAGE 6: Brake carriers with brake linings are fitted to the FR axle beam and taken to chassis assembled.
REAR AXLE ASSEMBLY: STAGE 1: Banjo casing from outside is unloaded and fixed on the conveyor and axle shaft is removed. STAGE 2: Brake lining and 10 bolt and washer are fixed on the brake carrier with spring washer. Dust cover is also fitted. STAGE 3: Brake nut and bolt are tighten and fitted 75 to 50 torques. STAGE 4:
Ring for oil seal is fitted on the hub shim is fitted 3-6tau for the clearance flange cover is fitted with 4 bolts.
STAGE 5: Inner oil seal is fitted on ring for inner oil seal. Inner wheel bearing is fitted. STAGE 6: Distance piece is fixed to align the inner and outer wheel bearing in the same axis. STAGE 7: Dry set, where the wheel hub is fixed roughly to verify whether to increase or decrease the shim. STAGE 8: WET SET Where grease is packed inside the wheel hub. STAGE 9: Axle tube nut is fixed with counter pin and bolt, 190 tau tightness. The given, studs are fixed in the hub to fixed to the shaft. Grease nipple is fixed on the wheel hub. STAGE 10:
Axle studs are tightened to 50-60 taus. Drum is fixed 8mm bolt is fitted.
STAGE 11: Axle shaft is fitted using 8 spring washer and nut on the stud. STAGE 12: Complete assembly of rear axle is unloaded and taken to chassis assembly.
CHASIS ASSEMBLY: DATE OF TRAINING:
23-04-2011
STAGE 1&2: Already assembled FR Axle & Rear axles from machine shop-4 are fixed on the main frame that fabricated from the machine shop 3 of the vehicle. STAGE 3: The fixed frame assembly is placed on the conveyor belt, where brake chamber is fitted to it. STAGE 4: Steering gear box is fitted to the main frame.
STAGE 5: Silencer tank is fixed to the main frame. STAGE 6: Then fuel tank is fitted in this stage of chassis assembly.
STAGE 7: Engine mounted on the main frame of the chassis of the vehicle. STAGE 8: Radiator fixed in front of the engine. STAGE 9: Tyres for all the wheels are fixed to the drums of the axles. STAGE 10: The vehicle is toed then and taken to the other unit to make it running conditions and test driven.
MACHINE SHOP II: DATE OF TRAINING:
26-04-2011
Here in this shop the perfectly casted part of crankcase arrives from the casting plant situated somewhere near the main plant. This casted crankcase constitutes the main part of the engine compartment. This shop-2 consist of the
heavy machines of HMT that helps in boring and drilling different sizes of holes needed for the fitments of various engine spares. There are different process of manufacturing is done here.
CONCLUSION: It’s been privilege to do in plant training in one of the India’s largest automobile producer ASHOK LEYLAND. It has helped in many ways to improve the knowledge about the actual work done in the industries and to have hands on experience. Thus we the students of murrugappa polytechnic college, Avadi have successfully attended and completed the training at ASHOK LEYLAND LIMITED ENNORE PLANT FROM 19.04.2011 TO 26.04.2011.
