SUMMER TRAINING PROJECT REPORT
INDIA YAMAHA MOTOR PVT. LTD.
SUBMITTED BY:-
PRABHAT TIWARI B.TECH MECHANICAL DEPARTMENT
SESSION: 2012-2016
DIT, AMITY GROUP OF INSTITUTION GREATER GREATER NOIDA, N OIDA, U.P (AFFILIATED TO UTTAR PRADESH TECHNICAL UNIVERSITY)
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I "%( ('/& !" &4p&ss ) a!'!%& !" a(( !*& p&"p(& *" p"3'& )& '!* s%pp"! a+ %'a+$& !*"%*"%! !*& $"%s& "# ) s%))& '+!&+s*'p p"a) ;'s!( I "%( ('/& !" !*a+/ Mr. Bhavesh Kuar
! *a3& 5&&+ p"ss'5(& !" $")p(&!& !*'s p"7&$!. I "%( a(s" ('/& !" !*a+/ Mr. A.K Shara #" p"3''+ )& !*'s "+&#%( "pp"!%+'! !" "/ '!* !*& YAMAHA #a)'(.
T*a+/ "% Pa5*a! T'a'
CONTENTS
1. Preface 2. Acknowledgement 3. Content 4. Overview 5. About Yamaha otor! 5.1. "i!tor# 5.2. About $ndia Yamaha otor! Pvt. %td &. anufacturing &.1. 'aw aterial &.2. (he manufacturing )roce!! &.3. *ualit# Control +. ,aridabad Plant +.1. -ear +.2. Cam!haft +.3. od# C#linder +.4. "ead C#linder +.5. A/le +.&. Connecting 'od +.+. Crank +.0. Crankca!e Cover 0. "eat (reatment
OVERVIEW
INDIAN AUTOMOBILE INDUSTRY O3& a p&'" "# )"& !*a+ !" &$a&s !*& I+'a+ A%!")"5'(& '+%s! *as 5&&+ '3'+ '!s "+ "!* !*"%* p*as&s. T*& &+! "# S%%/' C"p"a!'"+ '+ I+'a+ pass&+& $a )a+%#a$!%'+ 's "#!&+ p"'+!& as !*& ?s! s'+ "# I+'a !%+'+ !" a )a/&! &$"+"). S'+$& !*&+ !*& a%!")"5'(& s&$!" '!+&ss& ap' "!* &a a#!& &a. B (a!& @0>s !*& '+%s! &a$*& s&(#-&('a+$& '+ &+'+& a+ $")p"+&+! )a+%#a$!%'+ #") !*& s!a!%s "# (a& s$a(& ')p"!&. 9'!* $")paa!'3&( *'*& a!& "# &$"+")'$ "!* a!& '+&4 aa'+s! !*a! "# &a! ("5a( p"&s. I+'a *as 5&$")& a *%5 "# ")&s!'$ a+ &4p"! 5%s'+&ss. T*& a%!")"5'(& s&$!" *as 5&&+ $"+!'5%!'+ '!s s*a& *as 5&&+ $"+!'5%!'+ '!s s*a& !" !*& s*'+'+ &$"+")'$ p&#")a+$& "# I+'a '+ &$&+! &as. 9'!* !*& I+'a+ )'(& $(ass &a+'+ *'*& p& $ap'!a '+$")&, )"& p&"p(& a& &a !" "+ p'3a!& 3&*'$(&s '+$(%'+ $as a+ !"*&&(&s. P"%$! )"3&)&+!s a+ )a++& s&3'$&s *a3& 5""s!& '+ !*& sa(&s "# )&'%) a+ s'& $"))&$'a( 3&*'$(&s #" pass&+& a+ ""s !a+sp"!. S'& 5 s'& '!* #&s* 3&*'$(& sa(&s "!*, !*& a%!")"!'3& $")p"+&+!s s&$!" *as '!+&ss& 5' "!*. T*& ")&s!'$ a%!" $")p"+&+!s $"+s%)p!'"+ *as $"ss& %p&&s @000 $"&s a+ a+ &4p"! "# "+& *a(# s'& "# !*'s ?%& As p& S"$'&! "# I+'a+ A%!")"5'(& Ma+%#a$!%&s
ABOUT YAMAHA MOTORS
HISTORY Ya)a*as *'s!" "&s 5a$/ "3& a *%+& &as !" 1 *&+ T"a/%s% Ya)a*a #"%+& !*& $")pa+, *'$* 5&a+ p"%$'+ && "a+s. T*& Ya)a*a C"p"a!'"+ '+ apa+
12F$$ s'+(&-$('+& !"-s!"/&. I! as a $"p "# !*& G&)a+ D9 &s'+, *'$* !*& B'!'s* BSA C")pa+ *a a(s" $"p'& '+ !*& p"s!-a &a a+ )a+%#a$!%& as !*& Ba+!a).
A&*u( I%)"a Yaaha M*(*r Pv(. +(). Ya)a*a )a& '!s '+'!'a( #"a '+!" I+'a '+ 1@F. S%5s&%&+!(, '! &+!&& '+!" a F0:F0 7"'+!-3&+!%& '!* !*& Es$"!s G"%p '+ 1@@6. H"&3&, '+ A%%s! 2001, Ya)a*a a$%'& '!s &)a'+'+ s!a/& 5&$")'+ a 100 s%5s''a "# Ya)a*a M"!" C"., L!, apa+
MANUFACTURING
I+'a Ya)a*a M"!">s )a+%#a$!%'+ #a$'('!'&s $")p's&s "# 2 s!a!&-"#-!*&-a! P(a+!s a! ;a'a5a
RAW MATERIA+-
T*& p')a a )a!&'a(s %s& '+ !*& )a+%#a$!%& "# !*& 5" "# )"!"$$(& a& )&!a(, p(as!'$ a+ %55&. T*& )"!"$$(& #a)& 's $")p"s& a()"s! $")p(&!&( "# )&!a(. T*& #a)& )a 5& "3&(a' '!* p(as!'$. T*& !'&s a& $")p"s& "# %55&. T*& s&a! 's )a& #") a s+!*&!'$ s%5s!a+$&, s%$* as p"(%&!*a+&. T*& $('+& p's!"+, )a& "# a(%)'+'%) a((" 's a+ &ss&+!'a( $")p"+&+! "# &+'+&. I! 's ?!!& '!* p's!"+ '+s )a& "# $as! '"+. T*& $a+/s*a#! a+ $a+/$as& a& )a& "# a(%)'+'%). T*& &+'+& a(s" $"+!a'+s a $('+& 5a&(, !p'$a(( )a& "# $as! '"+ " ('*! a((".
THE MANUFACTURING PROCESS1. Ra )a!&'a(s as &(( as pa!s a+ $")p"+&+!s a'3& a! !*& )a+%#a$!%'+ p(a+! 5 !%$/. As pa! "# 7%s!-'+-!')& &('3& ss!&) "+ *'$* )a+ p(a+!s a& s$*&%(&, !*& )a!&'a(s a+ pa!s a& &('3&& a! !*& p(a$& *&& !*& a& %s& " '+s!a((&. 2. Ma+%#a$!%'+ 5&'+s '+ !*& &( &pa!)&+! '!* $")p%!&-$"+!"((& #a5'$a!'"+ "# !*& #a)& #") *'* s!&+!* #a)& )a!&'a(s. C")p"+&+!s a& #")& "%! "# !%5%(a )&!a( a+" *"((" )&!a( s*&((s #as*'"+& #") s*&&! )&!a( s*&((s #as*'"+& #") s*&&! )&!a(. T*& 3a'"%s s&$!'"+s a& &(& !"&!*&. T*'s p"$&ss '+3"(3&s )a+%a(, a%!")a!'$ a+ "5"!'$ &%'p)&+!. . I+ !*& p(as!'$ &pa!)&+!, s)a(( p(as!'$ &s'+ p&((&!s a& )&(!& a+ '+7&$!& '+!" )"(s %+& *'* p&ss%& !" #") 3a'"%s p(as!'$ 5" !') pa!s. T*'s p"$&ss 's /+"+ as '+7&$!'"+ )"('+. . P(as!'$ a+ )&!a( pa!s a+ $")p"+&+!s a& pa'+!& '+ 5""!*s '+ !*& pa'+! &pa!)&+! %s'+ a p"$&ss /+"+ as p"&-$"a!'+. A p"& $"a!'+ appaa!%s "/s ('/& a (a& spa-pa'+!&, 'sp&s'+ pa'+! !*"%* a p&ss%'& ss!&) &3&+( a$"ss !*& )&!a( #a)&. F. Pa'+!& pa!s a& s&+! 3'a "3&*&a $"+3&"s " !" )"!" !" ass&)5(& &pa!)&+! *&& !*& a& '+s!a((& "+ !*& #a)& "# !*& )"!"$$(&. 6. T*& &+'+& 's )"%+!& '+ !*& pa'+!& #a)&, a+ 3a'"%s "!*& $")p"+&+!s a& ?!!& as !*& )"!"$$(& 's s&+! "+ !*& ass&)5( ('+&. . 9*&&(s, 5a/&s, ''+ $a5(&s, #""! p&s, &4*a%s! p'p&s, s&a!s, sa(&5as, ('*!, a'"s a+ *%+&s "# "!*& pa!s a& '+s!a((& "+ !*& )"!"$$(& #a)&.
UA+ITY CONTRO+A! !*& &+ "# !*& )a+%#a$!%'+ ('+& a+ ass&)5( ('+&, %a('! $"+!"( '+sp&$!"s %+&!a/& a 3's%a( '+sp&$!'"+ "# !*& )"!"$$(& a+ '!s pa!>s ?+'s*'+, pa'+!& ?+'s* a+ ?! "# pa!s. T*& %a('! $"+!"( '+sp&$!"s a(s" #&&( !*& )"!"$$(&s '!* ("3& *a+s !" &!&$! a+ 5%)ps " &#&$!s '+ !*& ?+'s*. Ea$* )"!"$$(& 's !&s!& "+ a +a)")&!&. I+sp&$!"s a$$&(&a!& !*& )"!"$$(& #") 0-60)p*. D%'+ !*& a$$&(&a!'"+, !*& +" !&s!s #" a$$&(&a!'"+ a+ 5a/'+, s*'#!'+, *&&( a('+)&+!, *&a('*! a+ !a'(('*! a('+)&+! a+ #%+$!'"+, *"+ #%+$!'"+ a+ &4*a%s! &)'ss'"+s. T*& ?+'s*& p"%$! )%s! )&&! '+!&+a!'"+a( s!a+as #" p&#")a+$& a+ sa#&!. A#!& !*& +" !&s!, a ?+a( '+sp&$!'"+ 's )a& "# !*& $")p(&!& )"!"$$(&.
FARIDABAD PLANT
T*& )a+%#a$!%'+ %+'! "# ;a'a5a p(a+! $"+s!'!%!&s Cas("%/, Ma0h"%"%/, We')"%/, Hea( (rea(e%( a+ Pa"%("%/ "# pa!s "# !" *&&(&s "# IYM. ;"(("'+ a& !*& pa!s "# !" *&&(&s )a+%#a$!%&s '+ ;a'a5a P(a+! "# IYM:1. 2. . . F. 6. . . @.
G&a A4(& Ma'+ C('+& H&a C('+& 5" Ca+/ Ca+/$as& C"3& $a+/$as& Ca) a+ Ca) s*a#! C"++&$!'+ "
GEAR GEAR BLAN #") !*& 3&+" 's 5"%*! !" !*& ;a'a5a p(a+! #" )a+%#a$!%'+ "# &as. T*&+ '! 's pass& !*"%* !*& #"(("'+ p"$&ss&s: T%+'+,
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H*&&"%/ H"55'+ 's a )a$*'+'+ p"$&ss #" )a/'+ &as, sp('+&s, a+ sp"$/&!s "+ a *"55'+ )a$*'+&, *'$* 's a sp&$'a( !p& "# )'(('+ )a$*'+&. T*& !&&!* " sp('+&s a& p"&ss'3&( $%! '+!" !*& &a 5(a+/ 5 a s&'&s "# $%!s )a& 5 a $%!!'+ !""( $a((& *"5. C")pa& !" "!*& &a #")'+ p"$&ss&s '! 's &(a!'3&( '+&4p&+s'3& 5%! s!'(( %'!& a$$%a!&, !*%s '! 's %s& #" 5"a a+& "# pa!s a+ %a+!'!'&s. I! 's )"s! '&( %s& &a $%!!'+ p"$&ss #" $&a!'+ sp% a+ *&('$a( &a a+ )"& &as a& $%! 5 *"55'+ !*a+ a+ "!*& p"$&ss s'+$& '! 's &(a!'3&( %'$/ a+ '+&4p&+s'3&.
USES H"55'+ 's %s& !" )a/& #"(("'+ !p&s "# ?+'s*& ""s: • •
C$("' &a H&('$a( &as
• • • • • •
I+3"(%!& &a Ra!$*&!s Sp('+&s Sp"$/&!s Sp% &as 9") &as
H"55'+ 's %s& !" p"%$& )"s! !*"a!& ") *&&(s 5%! $&!a'+ !""!* p"?(&s $a++"! 5& *"55&. I# a+ p"!'"+ "# *"5 p"?(& 's p&p&+'$%(a !" a4's !*&+ '! '(( *a3& +" $%!!'+ $(&aa+$& &+&a!& 5 %s%a( 5a$/'+ " p"$&ss a+ '! '(( +"! $%! &((.
BROACHING ;" 3& (a& &as " sp('+&s a 3&!'$a( 5"a$* 's %s&. I! $"+s's!s "# a 3&!'$a( a'( !*a! $a'&s a s'+(& !""!* $%!!& #")& !" $&a!& !*& !""!* s*ap&. A "!a !a5(& a+ a Y a4's a& !*& $%s!")a a4&s a3a'(a5(&. S")& )a$*'+&s '(( $%! !" a &p!* "+ !*& Y a4's a+ '+&4 !*& "!a !a5(& a%!")a!'$a((. T*& (a&s! &a a& p"%$& "+ !*&s& )a$*'+&s. O!*& "p&a!'"+ s%$* as 5"a$*'+ "/ pa!'$%(a( &(( #" $%!!'+ !&&!* "+ !*& '+s'&. T*& "+s'& !" !*'s 's !*a! '! 's &4p&+s'3& a+ '&&+! 5"a$*&s a& &%'& !" )a/& '&&+! s'& &as. T*&&#"& '! 's )"s!( %s& '+ 3& *'* p"%$!'"+ %+s.
MARKING Ma/'+ 's "+& "+ !*& Pr"ar$ Gear a+ Gear Ba'a%0e We"/h(. I+ !*'s p"$&ss '+ )a/ 's )a& "+ a $&!a'+ 's!a+$& #") !*& $&+!& "# !*& &a "+ 5"!* !p&s "# &a s" !*a! a! !')& "# ass&)5( a(( !*& &a s*"%( 5& p"p&( )"%+!& s%$* as +" )'sa('+)&+! 's p&s&+! '+ &a ass&)5(, "!*&'s& !*& !a+s)'ss'"+ ss!&) "# 3&*'$(& #a'(s %'+ !*& "p&a!'"+.
CAMSHAFT Ca)s*a#!s $a+ 5& )a& "%! "# s&3&a( '&&+! !p&s "# )a!&'a(. T*&s& '+$(%& C*'((& '"+ $as!'+ a+ B'((&! s!&&(.
C*'((& I"+ Cas!'+: !*'s 's a "" $*"'$& #" 3"(%)& p"%$!'"+. A $*'((& '"+ $a)s*a#! *as a &s's!a+$& aa'+s! &a 5&$a%s& !*& $a)s*a#! ("5&s *a3& 5&&+ $*'((&, &+&a(( )a/'+ !*&) *a&. B'((&! S!&&(: *&+ a *'* %a('! $a)s*a#! 's &%'&, &+'+& 5%'(& a+ $a)s*a#! )a+%#a$!%&s $*""s& !" )a/& !*& $a)s*a#! #") s!&&( 5'((&!. O+& &4a)p(& 5&'+ EN05. 9*&+ )a+%#a$!%'+ a $a)s*a#! #") EN05, !*& $a)s*a#! '(( a(s" 5& *&a! !&a!& 3'a as +'!''+, *'$* $*a+&s !*& )'$"s!%$!%& "# !*& )a!&'a(. I! '3&s a s%#a$& *a+&ss "# FF-60 HRC. T*&s& !p&s "# $a)s*a#!s $a+ 5& %s& '+ *'*p&#")a+$& &+'+&s.
Pr*0esses Va'"%s p"$&ss '+3"(3& '+ !*& )a+%#a$!%'+ "# $a) s*a#! a$$"'+ !" "p&a!'+ )a$*'+&s a&: ;a$'+ T%+'+
"p&a!'"+ &a '(('+ a+ !app'+ "p&a!'"+ O'( *"(& '(('+ "p&a!'"+ Ca) '+'+ "p&a!'"+ G'+'+ "p&a!'"+ Lapp'+ "p&a!'"+ 9as*'+ "p&a!'"+
BODY CY+INDER B" "# $('+& "# &+'+& '+ )a& "# a'u"%"u '+ Cas("%/ sh*1 "# ;a'a5a p(a+!. I+ $as!'+ ('%' a(%)'+'%) 's p"%& '+!" !*& )"(, *'$* $"+!a'+s !*& *"((" $a3'! "# &s'& s*ap&, a+ !*&+ a(("& !" s"(''#. T*& s"(''# pa! 's /+"+ as casting *'$* 's &7&$!& " 5"/&+ "%! "# !*& )"( !" $")p(&!& !*& p"$&ss. I+'!'a(( '! *as p"" s%#a$& ?+'s* a+ &#&$!s, s" '! 's 5"%*! !" !*& Ma$*'+'+ s*"p #" '3'+ &s'& a$$%a!& ')&+s'"+ a+ s%#a$& ?+'s*. Ma$*'+&Op&a!"-'s& "p&a!'"+ "+& "+ !*& B" $('+& a&:-
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HEAD CY+INDER L'/& B" $('+& '! 's a(s" )a& %p "# A(%)'+'%) '+ $as!'+ s*"p a+ a$$"'+ !" '!s &s'& s*ap& !*&+ '! 's a(s" 5"%*! !" !*& Ma$*'+& s*"p #" &)"3a( "# &#&$!s, '3'+ )"& a$$%a!& ')&+s'"+ a+ s%#a$& ?+'s*. Ma$*'+&-'s& p"$&ss '+3"(3& '+ !*& )a+%#a$!%'+ "# H&a $('+& a&: Sp"!
#a$'+ a+ '(('+ M'(('+ a+ '(('+ R'*! ?4!%& E4*a%s! #a$'+, "%* %'& *"(& '(('+ J L&#! s'& '+(&! #a$'+%'& *"(& '(('+ R'*! s'& &4*a%s!, (&#! s'& '+(&! #a$'+ a+ !*&a'+ R'*! s'& &4*a%s!, (&#! s'& &4*a%s! 5"'+ a+ !*&a'+ R'*! s'& #a$'+, (&#! s'& '+(&! #a$'+, '(('+ a+ !app'+ R'*! s'& &4*a%s!, (&#! s'& '+(&! "$/& )'(('+ R'*! s'& &4*a%s!, (&#! s'& '+(&! pa&+! 5"'+ Pa&+! 5"& '+sp&$!'"+ R'*! s'& spa/ *"(& #a$'+, !*&a'+, (&#! s'& *"(& '(('+ a+ &a)'+ R"%* $a)5"&, #a$& )'(('+, '(('+ a+ !*&a'+ M'-as*'+ A' 5(" p"$&%& A' p(% a%& '+sp&$!'"+ S&a! a+ %'& p&ss
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A2+E MAIN T*& )&!*" '+$(%&s *&a!'+ a 5'((&! a! a *&a!'+ s!a!'"+ !" a p&&!&)'+& !&)p&a!%&, #"'+ !*& *&a!& 5'((&! a! a #"'+ s!a!'"+ !" #") a )a$*'+& a4(&. T*'s a4(& 's 5"%*! !" !*& ;a'a5a p(a+! #") 3&+" a+ p"$&ss& '+ )a$*'+'+ s*"p #" &s'& a$$%a!& s*ap&, ')&+s'"+ a+ s%#a$& ?+'s*. T*& p"$&ss '+3"(3&s a&: T%+'+ D&5%'+ D'(('+ O'(
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CONNECTING ROD A s!a+a s*ap& "# $"++&$!'+ " '!* p"" s%#a$& ?+'s* 's 5"%*! #") 3&+" !" !*& ;a'a5a p(a+! *&& *&&as "p&a!'"+ 's "+& "+ '! '+ Ma$*'+'+ a+ *&a! !&a!)&+! s*"p !"
'3& '! p"p& a$$%a!& ')&+s'"+, "" s%#a$& ?+'s* a+ *a+&ss. Op&a!'"+
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HEAT TREATMENT
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5& s!"& '+ a #&&& !" p&3&+! *a&+'+ %+!'( a#!& #%!*& "p&a!'"+-ass&)5( "# '3&!s, #" &4a)p(&, )a 5& &as'& '!* a s"#!& pa!.
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