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IN Industrial Engineering
ON SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE OF BACHELORS OF TECHNOLOGY IN MECHANICAL ENGINEERING
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ACKNOWLEDGEMENT
I hereby take this opportunity to thank those people who helped in successful completion of my training. This training gave me an opportunity to learn a lot of new things and meet great people who shall be held in great esteem. Firstly I would like to express deep gratitude & indebtedness to Mr.SANJAY BATRA, under whose supervision and hard-work I successfully completed my training at SWARAJ ENGINES LIMITED. He consistently helped and guided me in achieving the prime objective of my training. I also thank the teachers of the mechanical department of my college who consistently helped me. Last but not the least; I would like to thank the staff and work force of S.E.L who always gave their full co-operation in helping us to understand what we asked for.
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PREFACE
Training is an investment and hence should be able to get due returns in terms of better quality of workmen and Engineering for future. SWARAJ ENGINES LIMITED, M&M. today is one of the major Tractor Producer Industry, giving their best performing machines to their customers. As concerned with my Industrial training it is of my best opportunity during my Engineering to learn many things about the Automobile Industry through this Industry. During my training I got the opportunity to learn things that would pay to me in my near future. I pay thanks to the training faculty of our college and to staff and operators of SWARAJ ENGINES LIMITED for their co-operation during my Industrial Training.
Contents
Company profile 5-10
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Introduction to IE department Work done by the IE dept Types of Engines Manufacturing In SEL Components being machined Machine used in machine shop Operation being done Machine process of various components Crankcase Cylinder Head Gear Casing Cylinder Block
11 12 13-15 16 17 18 19 20-25 26-31 32-34 35-38 39 40-51 52-57 58-60 61-63 64-65 66
Project undertaken Process sheets SPC on sunkap machine Tool Life Time study
Layout
Bibliography
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COMPANY PROFILE
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INDUSTRY BACKGROUND
The Indian tractor industries as it now is a major segment of its engineering industry. However till 1947, Indian firms assembling semi knocked down (SKD) kits in collaboration with foreign manufactures met the tractor requirement of the country largely through imports and partly. Though the first tractor company was set up in India 1960, but the growth in real terms started from 1974, when the government banned the import of the tractors. Today India is the largest tractor producing and consuming country. In an effort to reduce imports and develop indigenous technology, the government, permitted setting up of the major manufacturing companies.
1. EICHER GOOD EARTH 2. TAFE 3. INTERNATIONAL TRACTORS 4. ESCORT TRACTORS 5. FORD TRACTORS 6. HMT 7. PUNJAB TRACTORS 8. KIRLOSKAR
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Keeping in mind Punjab agrarian economy it was decided by Punjab Government to encourage the growth of industries with complements Punjabs agriculture growth. The task was entrusted to P.S.I.D.C. and with dual objective of industrial and agriculture growth, PTL was established on 27th JUNE 1974.
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PTL setup the swaraj combine division (SCD) near chapper cheri village located in Tehsil Kharar, district Ropar of Punjab state. It was set up with capital outlay of Rs. 2.6 crores to manufacture self propelled harvesters or combines. In 1985 it also brought out diesel fork lifters of 2 tonnes and 2.5 tonnes lifting capacity. Later on the company entered into technical collaboration with Komatsu fork lift company of Japan for manufacturing both the diesel and electronic fork lifters of capacity up to 10 tonnes. In April 1995, it has also started production of Swaraj 922 tractors.
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DEPARTMENTS OF S.E.L.
INDUSTRIAL ENGINEERING MACHINE SHOP ASSEMBLY AND TESTING SHOP QUALITY SHOP MAINTENANCE SHOP TOOL ROOM STANDARD ROOM AND TOOL CRIB STORES
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INDUSTRIAL ENGINEERING
Industrial Engineering is the most important department in terms of production, planning, designing and optimization of methods governing the factory operations. It deals in utilization of resources i.e. manpower, machines, money etc. Hence it can be considered as the backbone of production industries. For a new industry I.E department plays an important role. Its main functions involve the planning of layouts of all the shops to get the maximum benefits of the available space, setting the time standards to perform particular job by micro motion study, implementing the company standards. All type of data collection and data analysis, setting the targets and try to achieve them etc. the other function of this department may involve selection of cutting tools machine tools, designing of jigs, fixtures and inspection of gauges etc.
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The Plant Manufactures five types of engines, which engines are sent to the swaraj tractor division, S.A.S. NAGAR. One of these is a single cylinder engine exclusively designed R&D plant of Swaraj. Out of rest one is two cylinder and others three cylinder engines. All the engines are Euro-3 and SEL is planning for modifications to be introduced, so that its engines may be Euro-4 compatible. The specifications of these engines are:
Engine Specifications:
Model : HP : RV-2 xm KIRLOSKAR 26.5 S.A.E.
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Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :
SWARAJ 724 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 110 mm 1728 cc 2000 rev/min Water Cooled
Engine Specifications: Model : HP : Tractor : Type : Bore and Stroke : Displacement : Rated Engine Speed : Cooling System :
RB-33 xm KIRLOSKAR 55 S.A.E. SWARAJ 855 FE 4 - Stroke, Direct Injection, Diesel Engine 100 X 116 mm 3308 cc 2000 rev/min Water Cooled with Oil Cooler for engine oil.
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Vertical milling machine Horizontal milling machine Radial drilling machine Gang milling machine Rough boring machine Semi-finish boring machine Finish boring machine Honing machine Gun drilling machine Washing machine Rotary grinder
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Rough milling machine XLO valve lapping machine Line boring machine
Grinding Drilling Semi-finish boring Finish boring Tapping Milling Chamfering Reaming Lapping Washing Assembly
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Honing Deburring
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CRANK-CASE:
Crankcase is the housing for accommodating crank shaft and cam shaft. In SWARAJ tractors, crank case is cast separately and attached to cylinder block. The bottom face of crank case walls is flanged to strengthen the casing and to provide a machined joint face for sump to be attached. Crank-shaft is supported in the crank case through a number of bearings called main bearings. The construction of the crank case has to be such as to provide very high rigidity because it must provide reactions for the heavy forces set up to gas pressure in the cylinders. The cylinder block is mounted above the crank case. At the top of the cylinder block is attached the cylinder head. Attached to crank case is sump, flywheel, gear casing, fuel filter, water separator etc. The material of crank case is cast iron because it has following advantages:1. Good foundry material
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2. High machinability 3. It does not warp under high temp. & pressure developed in cylinders 4. It is slightly porous nature as it retains better lubricant oil film 5. It does not wear too much 6. Sound damping properties 7. Low coefficient of thermal expansion 8. It is relatively cheap
1.
SUNKAP MACHINE :
This machine is first machine of crank-case line on this machine is used for milling of sump face, cap mtg. face, top face (RV2, RV3, RB30/RB33) of crank-case. Milling at all three faces is done simultaneously by three milling cutters.
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There are two machines used for same operation for increasing production rate. It is used for milling, drilling and boring operations on Sump face, Cap mating face, Fuel filter Separator mating face drilling
3.
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boring tools enter from both sides i.e. gear end side (GES) and flywheel end side (FWS).
8.
WASHING MACHINE:
After drilling main oil gallery, the washing of crank-case is done for removing chips etc from the gallery.
9. NOTCHING UNIT:
It is used for making a notch in crank bore in crank case. Notch is used for supporting bearing, which is used to avoid friction between cap face and crank shaft.
This machine is used for making various galleries, dipstick hole, oil pressure gauge hole etc.
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CYLINDER HEAD
Cylinder head is attached to the top of the cylinder block by means of studs fixed to the block. The gaskets are used to provide a tight leak proof joint at the interface of the head and the block. The cylinder head forms a combustion chamfer above each cylinder. It also contains injector holes and cooling water jackets. Besides valve openings are provided in the head. Upon which is also mounted the complete value operation mechanism. In all the cylinder heads of swaraj engines, the inlet and exhaust manifolds are placed on different sides of the cylinder head, it is called offset cross-flow type. Detachable head type has many other advantages over the integral construction.
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1. From production point of view, the cylinder block casting with open bore for the detachable type head, is much more simplified. 2. Operations like de carbonizing and value grinding are simplified 3. The comp. ratio can be changed slightly by changing the thickness of gasket used between the block and the head. The material used for cylinder head is cast iron There are separate sets of pipes attached to the cylinder head which carry the air and the exhaust gases. These are called manifolds. The cylinder has the nozzle bore in which the injector is inserted. The function of injector is to inject the fuel in the cylinder in properly atomized from and in proper quality. The cylinder head apart from having the inlet and exhaust manifolds (attached to cylinder head) has a water outlet manifold. On the top of cylinder head, is mounted the rocker arm, rockers shaft, push rods, springs rocker cover etc. The cylinder head also contains the inlet and exhaust valves. There is a water jacket in the cylinder head for the circulation of cooling water. The lubrication oil for the lubrication of rocker assembly enters from Rocker supply hole. Where it enters through rocker supply hole where it enters through rocker supply pipe from crank-case. RV2 and RV3 have the same cylinder head while RB30 and RB33 have the same. The S-15 has completely different cylinder head.
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Some of RV cylinder heads in finished state are brought from vendor while some in semi-finish state are brought and finished in cylinder heads of RB are brought from vendor in semi-finished state and finished in cylinder head section itself. The machining process of cylinder head is as follow:-
1.
CNC 600:
First operation of cylinder head is done on C.N.C. machine. It is used for facing of liner bore in the liner bore or liner boring, the liner resets.
2.
BENCH DRILL:
After liner boring chamfering on valve guide holes and counter in inlet valve guide is done on this machine.
3.
DUPLEX MACHINE:
After chamfering milling of inlet and exhaust face is done on DUPLEX MILLING MACHINE. The two pieces are clamped hydraulically and milling on two faces is done simultaneously with two cutters on both sides.
4.
After inlet and outlet face milling, boring of Valve guide and valve seat are done on boring machine. Two tools are used on each side for rough cutting and finish cutting.
5.
VMC-40:
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This machine is used for Valve guide and V. seat boring of RB cylinder head. And nozzle boring operation of both RB and RV cylinder heads are also done. In valve guides bore, the guides are inserted and guide the valve. In valve seat the valves rest.
6.
After nozzle boring four sides drilling of cylinder head is done on radial drilling machine.
7. CHAMFERING UNIT:
Here chamfering on all holes is done. Which are drilled on cylinder head in previous set-ups.
9.
Chamfer, Tap Gallery Washing and Core plug filter: Press valve guides and valve Seat inserts:
1. Place cylinder head on press table resting on top side.
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2. Clean valve seat inserts bores and valve seats with clean cloth properly. 3. Put one inlet valve seat insert in the mandrill and press in the respective bore (not used now). 4. Respect sr. no. 03 for exhaust valve seat insert. 5. Reverse the clamp. 6. Fit snap rings in valve guides with the help of hammer and special tool. 7. Press valve guide in valve guide bore with the help of tool.
10. Tap 1-hole M 101.5 and 10 deep. 11. Feed the comp. in the washing booth 12. Remove the comp from booth after washing 13. Clean the comp with air Jet and cloth. 14. Alloy lockset on care plug holes 15. Fit case plugs in core holes by hammer and punch
CuSO4.
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5. Press cups along with springs with the help of fixture on inlet valve. Side and exhaust valve side. 6. Insert collets pairs to take the proper seat with valve cup. 7. Test for leakage on valve leakage testing machine at air pressure of 4 kg/cm2 8. Re-lap the seats is leakage appears The emery paste is used in lapping process which acts as a grinder and grinder both valve and valve seat.
GEAR CASING
As the name suggests, gear casing is the casing for gears. It encloses the crank shaft gear, cam shaft gear, idler gear, FIP driving gear, lubricating oil pump assembly. It has following faces. 1. covering face or oil filler body mating face 2. crank- case mounting face 3. sump mating face 4. lubricating oil filter mating face 5. Plate face 6. Water pump mounting face
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Covering face: On this face, timing setter, tension lever, and pulley for driving crankshaft are mounted. Crank case mounting face: It is a face which meets with the gear end face of crank case. Sump face: On this face, sump is mounted. On water mounting face, water pump is mounted in RV2&RV3. but in case of RB30&RB33, the water pump is mounted on cylinder block. On this face alternator bracket is mounted in RV2&RV3. But in case of RB30&RB33, it is mounted on cylinder block
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4 drilled holes of 8.4 around FIP mating hole. Here FIP is mounted. Through FIP mating hole the FIP shaft passes on which adapter flange is mounted. With this adapter flange, the FIP driving gear is tightened Bearing hole accommodates bearing. The extended portion of gear casing where the plate is mounted accommodates the gear. This gear transmits motion to the hydraulic pump which is used for operating the lift hydraulic pump.
this machine the following operations are done on the oil filler body mating face. Here also two machines are used for same operation. Oil seal hole accommodates the end of shaft where oil seal is mounted which prevents the oil to come out of gear casing. On this end of crank- shaft, the pulley for giving a drive to it is mounted.
3. HMC-500
Third set-up of gear casing is done on H.M.C. machine. This machine is used for operations done on lubricating oil mating face, sump face, plate face and top face are done . Operations done are drilling chamfering & tapping .
4 .FLEXIARM:
The tapping of all faces are done on this machine by clamping in fixture specially designed for this operation& also side drilling is done.
5. WASHING MACHINE:
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After oil gallery drilling washing of gear casing is done on washing machine with coolant. Washing is done to remove chips and other components from oil galleries and other drilled holes. After washing cleaning of gear casing is done with air jet and de burring of gear casing is done.
CYLINDER BLOCK
It is an very important part of engine .In it liner with piston & connect & connecting rod assembly is placed.
1. FN2EV:
On this machine milling operation is done on top face.
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3. HMC:
On this machine milling , drilling ,boring & tapping operations are done.
SET UP 1: Finish milling alternator and cooler side using bottom as reference. SET UP 2: Rough milling top face, rough and finish milling sump face.
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Machine No. 12: SUNNEN Honing Machine Machine No. 13: Washing Machine
oil gallery and water jacket housing.
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PROJECTS
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UNDERTAKEN
Project no:1
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1. It provides information about feed,RPM, and depth of cut for a particular operation. 2 .It provides about tools,adapters, insertsalong with there stock numbers.
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3. It also provides the sequence of operations to be performed on those particular machines. 4. It provides us information of machine to be used,machine number, component,standard tools,special tools etc.
Here are some of S.O.P. sheets which i have up graded or audited in AVL cyl head process:
Project no:2
SPC on sunkap machine(286.01)
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In understanding a process, the process is typically mapped out and the process is monitored using control charts. Control charts are used to identify variation that may be due to special causes, and to free the user from concern over variation due to common causes. This is a continuous, ongoing activity. When a process is stable and does not trigger any of the detection rules for a control chart, a process capability analysis may also be performed to predict the ability of the current process to produce conforming (i.e. within specification) product in the future. When excessive variation is identified by the control chart detection rules, or the process capability is found lacking, additional effort is exerted to determine causes of that variance Once the causes of variation have been quantified, effort is spent in eliminating those causes that are both statistically and practically significant
SPC on Sunkap Duplex machine(286.01) Need : Variation in Size dimension 328+-0.1 and Dimension 15+- 0.1 from
component to component (maximum Variation 0.25mm)
PROCEDURE
1. Select the parameter (liner depth of cylinder block ) for which machine capability is to be calculated. 2. Give the SPC chart showing the upper scale tolerance limit & lower scale tolerance limit to the operator. 3. Operator is made to fill the readings on SPC chart at regular intervals.
ACTIVITY DONE
1.Component inspection (10 nos.) carried out for dim 328 at 4 points .
2.After the inspection the whole data is feeded For calculating the Machine capability which is called as CM. 3.The CM comes out to be 0.36.
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4. New Fixture for Sunkap was made for improving the CM of the sunkap machine. 5.Again the Component inspection (10 nos.) carried out for dim 328 at 4 points 6. Results are slightely better as the CM is increased to 1.37 7. Then the Component inspection (15 nos.) carried out for dim 328 at 4 points with different clamping pressure 8. Repeatbility Results are slightely better @ low clamping pressure
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Project no:3
Evaluate tool life of sunkap machine and Semi finish boring machine
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Tool life can be define as the length of time that a cutting tool can function properly before it begins to fail.
PROCEDURE:
Tool life of each tool used in sunkap & finish boring machine is calculated by making list of each tool that is used on these machines to make the required component.
Tool list of each tool is provided on each machine & operator is asked to fill the date & time of tool change.
After the data is collected about the date and time of tool change the next step is to fill the data into the table for calculating the tool life of sunkap & finish boring machine.
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Here are some table which i have up made for calculating the tool life .
Project no:4
Time study of RB CYLINDER BLOCK LEAK TEST.
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pneumatically. 7. Ensure the drain pipe in vertical position & fill the tank with coolant up to level marked
8. Observe the unit for 30 seconds for any air bubbles occurrence 9. After 30 seconds drain the coolant by operating the lever downward
12.Pick up the component from unit by inserting tackle & lifting up from unit
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13.Move the hoist to conveyors & unload the component on conveyor & draw back the tackle & move towards starting position
Project no:5
layout of machining line
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LAYOUT
From the beginning of the entrance of the industry it starts performing its job. The best optimum utilization of space .The most important and first task of IE in setting up a new industry or expanding the old industry in planning and make out the layout according to the process .At SEL , the expansion program has been carried out ,industrial dept.has played an important role in planning making the layout of various shops according to the requirements of the process & the target of making the new engines Layout on the machine floor for the foundation of machine fitting. Marking the final layout of the machine on the floor for the foundation of machine fitting.
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BIBLIOGRAPHY
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