Documente Academic
Documente Profesional
Documente Cultură
TRAINING
At
PUNJAB TRACTORS LIMITED,
MOHALI
PHASE-IV
ACKNOWLEDGEMENT
Before we get into the thick of fog, I would like to say that it was a
great pleasure & privilege for me to have the opportunity of undertaking the
training at PUNJAB TRACTOR LIMITED, MOHALI, for a period of 6
months as my 7th semester project work for the Bachelor of Tech. Education
at DEPARTMENT OF MECHANICAL ENGINEERING, S.U.S.C.E.T.
TANGORI. I would like to thank the PTL for providing me such an
opportunity.
Firstly I would like to express my deep gratitude to the Head of the
training department Mr. J SINGH for his continuous help & guidance during
the training tenure.
I am extremely grateful to Mr. M.C Gupta (Sr. manager vdc dept) who
helped me at every stage by providing mean opportunity to visit various
vendors.
My heartily thank to Mr. Purshotam k Sharma and Mr. S.K Saini who
were my project coordinator & my guide throughout the project works. They
always went out of their way to help me at all times. Their experience &
in
Indian
industry
is
only
post
independence
HISTORY
The Indian Tractor Industries, as it is now, is a major segment of its
engineering industry. However till 1974, Indian firms assembling semi
knocked down (SKD) kits in collaboration with foreign manufactures met
the tractor requirements of the country largely through imports & partly.
Though the first Tractor Company was set up in India in 1960, but the
growth in real terms started from 1974, when the government banned the
import of tractors. Today India is the largest tractor producing and
consuming country. In an effort to reduce imports & develop indigenous
technology, the government, permitted setting up of the major manufacturing
companies.
1.
2.
1960
1964
3.
International Tractors
1965
4.
Escorts Tractors
1966
5.
Ford Tractors
1971
6.
7.
HMT
Punjab Tractors
1973
1974
8.
9.
Kirloskar
Harsha
1974
1975
10
Auto Tractors
1981
.11.
Universal Tractors
1982
TERRITORY
32%
26%
10%
12%
20%
SEGMENTWISE
HP Range
Up to 30 HP
19%
31-40 HP
51%
Above 40 HP
30%
PTLS BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab Govt.
to encourage the growth of industries which complements Punjabs
agricultural growth. This task was entrusted to P.S.I.D.C. that was played a
major role in bringing Punjab to threshold of industrial revolution. With the
dual objective of industrial & agricultural growth, P.T.L. was established on
27th June 1974.
LOCATION
The factory is located at S.A.S. Nagar, the important industrial town of
Punjab, 5 kms. from Chandigarh. This factory was among the first to be set
up in this industrial town. The company is managed by board of Directors,
while the day to day operations are managed by Vice chairman & M.D. of
the company.
GROWTH OF PTL
PUNJAB TRACTOR LIMITED started with an annual capacity of
five thousand tractors & with a capital of Rs. 3.7 crores. It went into
commercial production in the year 1974; its first production was 26.6
BHP tractors given the name SWARAJ-720. Ever since then P.T.L. has
not looked back. In the first twenty years of existence its capacity has
been increased to 24,000 per annum, which is a considerable
achievement by any standards. Besides tractors, it has added a host of
other products to its range, which includes:
Harvesting Combine.
Fork Lifters.
Agriculture implements.
Automotive casting.
second largest player after M & M in FY2001 with a market share of 18.1%.
PTL tractors are sold under the Swaraj brand name. PTL has strong market
share of around 20% in the northern region with the highest share in Punjab
and Haryana and 16% in the western regions and southern regions of India.
In the east the company accounts for 11% market share. The tractor sales
accounted for 83.3% of PTL's turnover in FY2001 whereas the harvestercombines, forklifts and spare parts accounted for the balance. Industry
basics The Indian tractor market is dominated by low price, rugged,
versatile and low to medium powered tractors; the main reason being the
inability of farmers to invest in farm mechanization. Tractors are categorized
on the basis of horse power (HP) of the engine. In India, the popular range of
tractors is 20-40 HP compared to 60 HP in Europe and 90 HP in the USA.
Though large tractors were economically unviable in India, there has been
an increasing demand for high-powered tractors due to soil conditions,
particularly in states of MP, Gujarat and Maharashtra. But more recently,
higher-powered tractors are also being sold in states like Punjab where it is
considered as a status symbol. Tractors available in India are 1/4th of the
prices of similar powered tractors internationally or in developed countries.
Availability of credit is the most crucial factor impacting tractor demand, as
in India 90% of the tractors are financed by bank credit at concessional rates.
Increased use of irrigation facilities, shift towards multi-cropping,
consolidation of lands holdings, promotion of co-operatives and higher
investment in agriculture also contributes to higher tractor demand. The
tractor segment comprises players like Eicher, Escorts, HMT, Punjab
Tractors, M&M, TAFE, Sonalika, which control about 98% market
share. India is the worlds largest market in tractors since 1996. A few
international players like Case New Holland, John Deere and Steyr have also
set up facilities in India. But these players have entered the higher-powered
category and, thus, pose little threat to the existing players who enjoy
advantages of established distribution/service network and strong brand
equity.
and
establishes
Punjab
Tractors
Ltd.
(PTL)
for
its
commercialization.
1971-73: PTL sets up SWARAJ Project for 5,000 tractors per annum at a
capital outlay of Rs. 37.0 million with an equity base of Rs 11.0 million.
1974: Swaraj 724 (26.5 HP) tractor commercially introduced.
1975: 2nd tractor model SWARAJ 735(39 HP) developed by own R&D,
commercially introduced.
1978: 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D,
commercially introduced. Maiden equity divided declared.
1980: Guided by social concerns and responsibility, PTL takes over PSIDC's
sick scooters unit - Punjab Scooters Ltd. (subsequently renamed as
SWARAJ Automotives Ltd.) India's first Self propelled Harvester Combine
- SWARAJ 8100 developed by own R&D, commercially introduced.
SWARAJ Foundry Division set up in backward area.
1983: 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D,
INTERNATIONAL
AND
NATIONAL
SWARAJ TRACTORS DIVISION:It is located in Phase-IV, SAS Nagar. The construction work of PTL was
started in March 1972 and the first batch rolled out on 14 th November 1973.
It started with an annual capacity of 5000 tractors with a capital of Rs. 37
million. In 1974 it went into commercial production with Swaraj 724 26.5
BHP tractors as its first model. During its 22 year of production, it has not
only expanded its manufacturing capacity to more than 24000 tractors per
annum but adds more products into its manufacturing range. Its product
range includes the following.
Swaraj 724
26.5 BHP
1974
Swaraj 735
39.0 BHP
1975
Swaraj 720
19.5 BHP
1985
Swaraj 855
55.0 BHP
1987
Swaraj 744
44.0 BHP
1995
Swaraj 733
33.0 BHP
2000
Swaraj 939
35.0 BHP
2004
Swaraj 834
34.0 BHP
2005
Swaraj 978
78.0 BHP
2005
1. SWARAJ 724
24.0 BHP
2. SWARAJ 733
33.0 BHP
3. SWARAJ 744
44.0 BHP
4. SWARAJ 722
22.0 BHP
5. SWARAJ 735
35.0 BHP
6. SWARAJ 855
55.0 BHP
7. SWARAJ 939
39.0 BHP
8. SWARAJ 978
78.0 BHP
9. SWARAJ 834
34.0 BHP
10.SWARAJ 957
57.0 BHP
RV2
-----------
two cylinders
24 B.H.P.
2.
RV3
-----------
three cylinders
; 39.5 B.H.P.
3.
S15
-----------
Single cylinder
25 B.H.P.
4.
RB33
-----------
three cylinders
55 B.H.P.
5.
RB30
-----------
three cylinders
44 B.H.P.
These engines are sent to the Swaraj tractor division where these are fitted
on various model tractors. The S-15 engines are manufactured in the Swaraj
combine division and are fitted on Swaraj 722 model tractors.
INTRODUCTION
The manufacturing of Tractor is performed in various steps. It is
manufactured after passing through various processes in various shops.
Firstly, various operations on various parts are performed in the L.M.S.
(Light Machine Section) and H.M.S. (Heavy Machine Section). In H.M.S.
generally there are four major heavy parts that are given proper machining
operations. These include Gear Box Casing, Differential Housing, Trumpet
Housing and Rear Cover. Similarly, in L.M.S. the light parts are given
proper machining. These include various parts such as Gears, Shafts, Cage
Assembly casing etc.
In Heat Treatment Shop, the light parts such gears, shafts etc are
given the heat treatment to ensure their strength. Firstly the part after passing
through various operations in L.M.S. is taken to the Heat Treatment Shop.
Here the part is kept in the furnace for suitable time period up to certain high
temperature. Then it is taken to the Quenching tank where it is dipped in the
oil tank. After that it is taken to washing tank for washing of dirt and oil etc.
checking for vibrations, noise, brakes, oil level and other factors that effects
the performance of tractor.
At last there is pre-dispatch inspection done by quality department. Touching
of paint removal of bubbles from stickers etc is done here.
M/C Description
Job
Operations
Gear Line
Bull Gear
Bull Gear
Bull Gear
Turning
Cutting Internal Spline
Cutting Outer Spline
4.
ECO-5 CNC
Broaching machine
Gear hobbing
machine
Deburring machine
Bull gear
5.
Shaving
Bull Gear
machine
finishing
Bull
Pinion Shaft
Line
BP shaft
Facing, Centering
BP shaft
8.
Center Facing
machine
Femco Turning
machine
Femco WNCL-30
9.
COOPER
BP shaft
10.
11.
HMT H400
Shaving machine
BP shaft
BP shaft
Gear cutting
Shaving
Right cage
Cage assembly
Drilling, Chamfering,
Grooving, Tapping,
Facing
Boring (both sides)
Cage assembly
Grinding
Cage assembly
Cross drilling
6.
7.
Cage
Assembly
12.
VMC-40
13.
Boring machine
14.
BP shaft
15.
Cylindrical
Grinding machine
HMT HMC-320
Other
Machines
16.
Lichberr (HMT)
Hobbing
Gear cutting
17.
18.
Cooper
Parisuda AHG 80
CNC
HMT Radial drill
GCI 300 CNC
VMC-500 vertical
milling machine
WIDMA drilling
Cutting
Grinding
Bevel Gear
drilling
Grinding
Milling, Drilling
19.
20.
21.
22.
Drilling
23.
24.
machine
SPILOTE
PS-180
25.
Gear shaper(not
bevel)
tool.
Broaching: It is the method of metal removal by a tool that has
successively higher cutting edges in a fixed path. Each tooth
removes a fixed amount of material.
Drilling: It is the process of making hole in an object by forcing a
grind means to abrade to wear away by abrasion or to sharpen. In
grinding the metal is removed by the means of rotating abrasive
wheel it is rotating a rotating tool called drill.
Boring: It is the process of enlarging a hole that has already been
drilled.
Grinding: It is generally used for sharpening the cutting tool,
grinding threads and better surface finish etc.
Shaping: The process of cutting gears on the shaper is known as
Shaping. The tool used in shaping for teeths cutting is a multipoint cutting tool.
Hobbing:
Hob: - Hob is a cutting tool used for cutting gears or similar form
gears by the generating principle.
A Hob resembles a worm in appearance its cutting teeth on
the outside of a cylindrical body following a helical path
corresponding to the thread of a worm. It is useful to think of a hob
as a cylinder with a series of racks being parallel to the hob axis or
nearly so and each one slightly displaced axially with respect to the
preceding racks. As the hob rotates in fixed rotation with the blank
each row of teeth successively cuts the next portion of the gear
tooth spaces.
Hob material: 1.
2.
3.
4.
Carbide.
5.
Tool steel.
Trumpet housing
CONCEPT OF DOWELLING
The main aim or purpose of doweling is to act as a guide to the work
piece setting proposes prior to machining. Use of this process helps in
reducing the setting time considerably during machining of heavy
components. It is very difficult to set the work piece in required position
prior to machining, this process is very time consuming, hence when
initially the cast piece is brought dowel holes are drilled which act as the
pivot around which the whole machining takes place. Dowel hole act as the
reference point for machining of all the other holes on the work piece all the
operation to be performed on the work piece are taken in reference to the
dowel holes thus the hole act as the reference to all the operations.
REFERENCING:
Dowel act as reference, all the dimension of the work piece i.e. all
Types of machines:
Sr.No.
1.
2.
3.
M/C Description
Operations
Milling
HMC 500
Internal milling,
drilling CD hole (39 mm
for outer,
24.2 for
inner),
4.
5.
6.
7.
8.
Boring machine
Rough Boring
Boring machine
Finish Boring
Turning Lathe
Turning
Cross hole
Drilling
HMT HDC-S
inner 2
outside)
9.
10.
11.
Turning
Finish turning
Drilling, Reaming,
Tapping,
Chamferin
g
Trumpet Assembly
12.
13.
14.
15.
16.
17.
Rear
Rough Boring
Boring machine
Finish Boring
HMT SBCNC 35
SPM
Drilling, Tapping
Milling, Drilling,
Tapping
Cover Assembly
18.
19.
20
21.
22.
Milling(1 Vertical,2
horizontal
)
Milling
VA 50
Drilling, Milling,
Tapping
XLO
2.
3.
desired purposes.
Improve machinability.
2.
3.
4.
5.
Tempering
6 Case Hardening
a) carburizing
b) Cyaniding
7 Induction Heating.
ANNEALING:Annealing means softening of the material by heating and cooling process.
The cooling stage may be performed by regulating the fall of the
temperature in the furnace or by buried the article in sand or lime, and
quenching in oil or water, according to the material being treated.
NORMALISING:In this process the material is heated steadily through out its mass to just
beyond the critical temperature, and then withdrawn from the furnace and
allowed to cool in still air. With the normalizing process there is not soaking
period, for the work is held at the desired temperature for a period only
sufficient to give uniformity through out the mass.
Main purposes of the normalizing are:
1 To remove the effects of previous over heating and thus place the
material in good mechanical condition.
2 To remove the internal stresses caused by cooling from the molten state,
by cold working or by rough machining.
3 To soften the work prior to further hardening or tempering.
HARDENING:The operation of hardening is applied to all the tools and some important
machine parts intended for especially heavy duty service, as well as to all
machine parts made of alloy steel. Hardening of steels is done to increase
QUENCHING:Quenching is the act of rapidly cooling the hot steel to harden the steel. Oil
is used when a slower cooling rate is desired. Oil quenching results in
fumes, spills, and sometimes a fire hazard.
TEMPERING:It is an operation to reduce the internal stress and brittleness. With plain
carbon steel, tempering operation consist in slowly heating the hardened
material from room temperature up to maximum of about 600 oC and then
quenching in water or oil, the temperature and length of soaking period
being dependent in service requirement. Thus if plain carbon steel is to be
CASE HARDENING (CARBURISING):It is method of producing hard surface on steel. The steel used for this
purpose is usually a low carbon steel of about 0.15% carbon, which does not
respond appreciable to heat treatment. In course of the process, the outer
layer is converted into high carbon steel with a carbon content ranging from
0.9% to 1.2% carbon.
INDUCTION HEATING:It means the heating of ferrous metal by induced electrical current prior to
the hardening quench. In this process, analysis of the surface steel is not
changed, the hardening being accomplished by an extremely rapid heating
and quenching of the wearing surface which has no effect on the interior
core. The hardness obtained is the same as obtained in conventional
treatment and depends upon carbon content.
The heating effect is due to the induced eddy current in water or oil,
the temperature and length of soaking period being dependent on service
requirement. Thus, if plain carbon steel is to be hard without any appreciable
ductility, a temperature of about 150oC will be required.
SHOT BLASTING:Bombarding the component with lead filings does shot blasting. The reason
for shot blasting is to clean the surface i.e. removes scales and unwanted
material from the component.
This process of case hardening is use to harden the gears & shafts of the
tractor. But we know that as the hardness of any substance increases, the
brittleness of the material is also increases.
PAINT SHOP
Paint Shop is the place where the different sheet metal components
are painted. They are made to pass through various chemicals before they
are actually painted. The painting method opted is that of Spray Painting.
NEED FOR PAINTING: Long life
Rust resistance
Better look (more appealing)
The various operations performed in paint shop are:
Surface Preparation (Pre Treatment Cell) - carried out for sheets and
rims.
Painting JOST 1(dash board, rear frame, front shield, top bonnet),
JOST 2(fenders, side panel), CHASIS BOOTH (washing, primer,
washing zones), FINAL TOUCH UP.
Inspection
Rejection (Reprocessing)-for sheets and rims.
CHEMICAL
H.D.S-5
CONC
65-70
DIP TIME
5-7minutes
Derusting
Phosphating+Tunn
Rusto-225
Phos-509
12-17
30(+-2)
5-7minutes
7-8minutes
er (KNO3)
Surface activation
S.C.C
PH 8-9
1 Dip
Passivation
SEALANT-27
1-2
1 Dip
Dryer
3-4 minutes
Phosphating (done so as to form a thin layer of coating on part so
that no surface remains unpainted)
Rinsing
Passivation (done so as to avoid paint penetrating through certain
section of part bodys surface)
Drying
PAINTING:The process (sheet and rim painting) includes
Full Primer + one coat of paint (30-40 microns)
Flash off (This is the distance given so as to allow paint to dry)
Baking (120-130 degree centigrade)
Rubbing
Cleaning with tag rag
Final painting
Flash off
Baking
CHASIS PAINTING:-
Washing
Drying
Primer painting
Flash off
Final painting
Flash off
Baking
After painting inspection is carried out inspection is carried out and the
product is passed or rejected
Various parameters checked are:
Depth of penetration of paint
Thickness of paint coating
Smoothness
Uniformity
Less paint
Pin hole
Crow footing
Shade Variation
Dust
Vender fault
ASSEMBLY SHOP
The Assembly at SWARAJ TRACTOR DIVISION deals with the
assembly of tractor models 722, 724, 733, 735, 744, and 834. Assembly is
the joining of various constituents to form a final product. The assembly
process is carried out on the main line, which has various sub assemblies
along its length. Assembly shop can be divided in two main areas: 1)
2)
CLASSIFICATION OF ASSEMBLY AREA: The area before painting can further be divided into sub assemblies/ loops
namely
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.
DIFFERENTIAL LOOP:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.
GEAR BOX LOOP:-