SUMMER TRAINING PROJECT REPORT

ESCORTS INDIA PVT. LTD. AGRI MACHINERY GROUP, FARIDABAD

METHODS INVOLVED IN THE PROCESS OF PRODUCTION OF REAR AXLE

Project HeadMr. SUNIL KUMAR

PRODUCTION HEAD, REAR AXLE. CELL

Prepared By :

VIJAY ROYRoll No. - 0909040124B-tech - MechanicalIEC College, Greater NoidaUttar Pradesh

PREFACE

Industrial exposure is the most crucial part of the technical studies in which a

student is able to synchronize his technical knowledge with practical

knowledge gained in any of the organization in which he gets his training

from. I was allotted a project titled, “Methods involved in the process of

Production of REAR AXLE, in ESCORTS INDIA PVT LTD, FARMTRAC DIVISION”.

I hope that the word of my project communicates the actual experience

gained with subtlety and precision, which is unapproachable, by any other

means. From the medium of this project report, I would like to thank each and

every honorable employee of ESCORTS INDIA PVT LTD FARMTRAC DIVISION,

who has helped me to gain all the knowledge in the respective production

shop, where production process was involved.

INDEX

Company Profile

The Founding Philosophy

Background

Overview – Manufacturing

Overview – Material Management

Methods Involed

Design

Final Inspection

COMPANY PROFILE

ABOUT THE COMPANY

The Escorts Group is among India's leading engineering conglomerates operating in

the high growth sectors of agri-machinery, construction & material handling equipment,

railway equipment and auto components.

Having pioneered farm mechanization in the country, Escorts has played a pivotal role in

the agricultural growth of India for over five decades. One of the leading tractor

manufacturers of the country, Escorts offers a comprehensive range of tractors, more than

45 variants starting from 25 to 80 HP. Escort, Farmtrac and Powertrac are the widely

accepted and preferred brands of tractors from the house of Escorts.

A leading material handling and construction equipment manufacturer, we manufacture

and market a diverse range of equipment like cranes, loaders, vibratory rollers and forklifts.

Escorts today is the world's largest Pick 'n' Carry Hydraulic Mobile Crane manufacturer.

Escorts has been a major player in the railway equipment business in India for nearly five

decades. Our product offering includes brakes, couplers, shock absorbers, rail fastening

systems,composite brake blocks and vulcanized rubber parts.

In the auto components segment, Escorts is a leading manufacturer of auto suspension

products including shock absorbers and telescopic front forks. Over the years, with

continuous development and improvement in manufacturing technology and design, new

reliable products have been introduced.

Throughout the evolution of Escorts, technology has always been its greatest ally for

growth. In the over six decades of our inception, Escorts has been much more than just

being one of India's largest engineering companies. It has been a harbinger of new

technology, a prime mover on the industrial front, at every stage introducing products and

technologies that helped take the country forward in key growth areas. Over a

million tractors and over 16,000 construction and material handling equipment that have

rolled out from the facilities of Escorts, complemented by a highly satisfied customer

base, are testimony to the manufacturing excellence of Escorts. Following the globally

accepted best manufacturing practices with relentless focus on research and development,

Escorts is today in the league of premier corporate entities in India.

Technological and business collaboration with world leaders over the years, Globally

competitive indigenous engineering capabilities, over 1600 sales and service outlets and

footprints in over 40 countries have been instrumental in making Escorts the Indian

multinational. At a time when the world is looking at India as an outsourcing destination,

Escorts is rightly placed to be the dependable outsourcing partner of world's leading

engineering corporations looking at outsourcing manufacture of engines, transmissions,

gears, hydraulics, implements and attachments to tractors, and shock absorbers for heavy

trailers.

In today's Global Market Place, Escorts is fast on the path of an internal transformation,

which will help it to be a key driver of manufacturing excellence in the global arena. For this

we are going beyond just adhering to prevailing norms, we are setting our own standards

and relentlessly pursuing them to achieve our desired benchmarks of excellence.

THE FOUNDING PHILOSOPHY

Over six decades back two young men set out on a journey together armed with little

beyond intelligence, business acumen and determination and dreams aplenty. They

believed that India could only achieve total freedom with a breakthrough in the field of

agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had

kindled the hope that one day they would make a mark of their own. They were in fact

writing the first chapter of what has come to be widely recognized as one of the greatest

success stories in Indian industry.

Escorts came into being with a vision. A vision that eschewed easy paths to profitability,

and sought instead for ways to make a contribution. A vision that led two young brothers,

Yudi and Hari Nanda, to branch out of their family's prospering transport business and

institute ventures that were to become the foundations of Escorts Limited. On 17th

October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi

Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting

marketing house driven by the same business philosophy, which had given their family

enterprise an unrivalled reputation: customer concern. Not long afterwards, this driving

ambition to go beyond the expected led Hari Nanda to the first of his many successful

business insights - the discovery of the great business potential that lay in India's villages.

This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda

as Director. Though separate business entities then, both companies had two great

strengths in common: the dynamic Nanda brothers and the unifying force of the name they

gave their companies; Escorts, literally 'escorting' their products and services to the

customer while most other businessmen were just selling.

Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit remained embedded

in the foundations of the company. Mr. H P Nanda then took on the mantle to realize the

dreams which he had always seen with his brother.

Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged in 1953 to create

a single entity -Escorts Agents Pvt Ltd. Having initially started with a franchise for

Westinghouse domestic appliances, by this time the Company had already expanded its

marketing and service operations, representing internationally known German and

American organizations such as MAN, AEG, Haniel & Leug, Knorr Bremse, MIAG and BMA

for sophisticated electrical and mechanical engineering equipment and Minneapolis Moline

and Wisconsin for agricultural tractors, implements and engines. Escorts made a major

thrust into the agricultural arena by taking on the marketing and service franchise for

Massey Ferguson tractors in Northern India, which soon comprised 75% of MF's all-India

sales - a signal tribute to Escorts' inherent strengths. Its first industrial venture came up in

1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings and

cylinder liners - followed by production of pistons in collaboration with MAHLE, also of

Germany, in 1960. The company's incorporation in its present name, Escorts Limited, was

effected on 18th January, 1960. Escorts' next major industrial activity was the assembly of

tractors in 1961 in technical cooperation with URSUS of Poland. Subsequently this led to

the manufacture of the country's first indigenous tractors under Escorts' own brand name,

which were to play a pivotal role in the Green Revolution. This went on to lay the

foundations that even today are the Company's core strengths -relevant, world-standard

technology through strategic international alliances; a broadbased marketing and service

network yet unrivalled.

Beyond the growth of the organization, these principles have ensured that Mr. H. P.

Nanda's contribution to the cause of industry and the consumer will endure. He pioneered

the revolutionary concept of 'interdependence' between ancillary and large industries,

institutionalizing vendor development and in the process building Faridabad and the entire

belt of townships in the region. He introduced the discipline of service going before

marketing, reassuring the customer that Escorts would stay with them, that they were here

for the long run. He built lasting alliances with an array of the world's most respected

names in tractors, industrial equipment, two-wheelers, construction equipment and

telecommunications. Going further, he created institutions devoted to value engineering

and training, not only as investments in the company's future but also as catalysts for the

enhancement of Indian industry as a whole the Escorts R&D Centre and the unique Escorts

Institute of Farm Mechanization. His concern extended to the society in which he worked,

and he manifested it by establishing the Escorts Medical Centre at Faridabad, Escorts Heart

Institute and Research Centre at New Delhi, as well as numerous village development

programmes. And above all, he imbued the corporation with his own pioneering.

Escorts is testimony to the valor, vision and values of its Founder Mr. H P Nanda. He

remains the inspiration for our courage, spirit of adventure and ability to ‘Think Big’. These

qualities are his enduring legacy and have inspired and encouraged us down the decades

and will continue doing so in all our endeavors.

Background

In 1960, our parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture into tractors.

In 1965, we rolled out our first batch of tractors under the brand name of Escort.

In 1969 a separate company, Escorts Tractors Ltd., was established with equity participation of Ford Motor Co., Basildon, UK for the manufacture of Ford agricultural tractors in India.

In the year 1996 Escorts Tractors Ltd. formally merged with the parent company, Escorts Ltd.

Since inception, we have manufactured over 1 million tractors.

Overview – Manufacturing

Escorts - AMG has Tractor manufacturing capacity of 98,940 trs / annum which is the highest in Asia at one location. Its manufacturing operations are divided in three plants as

Component Plant

Tractor Assembly Plant

Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings such as Engine blocks, Gear Box housings, Differential housings are being machined along with Gears & Shafts. Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centers, CNC Turning Centers and variety of other precision machines, including Gear Hobbing and Shaving machines, etc. It is important to note that all critical components are machined in house.

Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line. Farmtrac Line is a composite line that has machining as well as assembly activities of Engine, Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine, Transnmission& Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that includes AVL make Eddy Current Dynamometers in Engine Test House.

Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all Tractor models are being machined. It has State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as well as Assembly activities where critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State of the Art Honing and other precision machines.

Overview – Materials Management

Presently procuring materials for 72,000 tractors per annum.

Present procurement value over US$ 30 million.

Production will rise to 100,000 tractors per annum in 2 years.Procurement value will rise to almost US$ 45 million in that period.

Presently 387 suppliers of which over 95% are India domestic.

Advantages of low costs of materials in India.

Items procured are:

Castings

Forgings

Machined Parts

Proprietaries

Sheet Metal

Hardware

METHODS INVOLVED IN THE PROCESS OF

PRODUCTION OF REAR AXLE

DESIGN OF THE REAR AXLE SHAFT

REAR AXLE PRODUCTION UNIT

S. No OPERATION DESCRIPTION

MACHINE EQUIPMENT

OPERATION CYCLE TIME(MINUTES)

1 FINISH TURNING OF BIG END FLANGE

NCL-15; NCL-16KWS MAKE CNC LATHE

1. DRUM DIA2. BIG END FLANGE DIA3. LENGTH OF DRUM

DIA4. FLANGE WIDTH5. LENGTH OF SEAL DIA6. LENGTH OF BEARING

DIA7. THREAD SIZE8. THREAD LENGTH9. LENGTH OF SPLINES10. LENGTH OF SEAL DIA11. STEM DIA12. FILLET RADIUS OF

STEM TAPER DIA13. SURFACE FINISHING

OF STEM TAPER DIA

8.99(57 JPS)

2. DRILL AND FINISH HOLE MILL 8 NOS BOLT HOLES THROUGH AND DRILL 2 NOS MANUFACTURING HOLES

HMD-19BATLIBOL MAKE MULTIDRILLING MACHINE

1. BOLT HOLE DIA2. BOLT HOLE CO-

ORDINATES3. MANUFACTURING

HOLE DIA4. MANUFACTURING

HOLE CO-ORDINATES

4.25(124 JPS)

3. FORM OIL GROOVE ON STEM END FACE

ETL-01 1. OIL GROOVE DEPTH2. OIL GROOVE PROFILE

3.43(140 JPS)

4. CHAMFERING OF BACK FACE OF 8 NOS BOLT HOLES

VLM-03 1. CHAMFER DIA2. CHAMFER ANGLE

3.43(140 JPS)

5. MILLING OF 38 INVOLUTE SPLINES ON STEM END

SMM-02HURTH MAKE SPLINE MILLING MACHINE

1. NO OF SPLINES DIA OVER MEASURING PINS.

2. PCD RUNOUT3. LENGTH OF SPLINES

3.55(104 JPS)

6. WASHING OF COMPONENT

WSM-01THERMAS MAKE

1. EFFECTIVE CASE DEPTH ON STEM

2. EFFECTIVE CASE

5(80 JPS)

WASHING MACHINE

DEPTH TOWARDS FLANGE DIA

3. EFFECTIVE CASE DEPTH AT REST DIA OF SPLINES

4. EFFECTIVE CASE DEPTH AT ROOT OF M-642 THREADS

5. HEAT RUNOUT ON SPLINED END

7. INDUCTION HARDENING OF SHAFT STEM

IHM-03IHM-04

1. QUENCHING MEDIA2. TEMP OF

QUENCHING MEDIA3. PRESSURE OF

QUENCHING MEDIA4. RADIAL GAP B/W

INDUCTOR & COMPONENT

5. FACE GAP B/W INDUCTOR AND COMPONENT

6. QUECH LAG TIME7. PRE HEATING TIME8. POWER REQUIRED9. SPINDLE SPEED10. INDUCTOR

TRANSVERSE RATE8. CHECK FILE

HARDNESS AT NECK & STEM

9. NORMALISE THE SHAFT IF REQUIRED FOR REWORK

IHM-04INDUCTION HARDENING MACHINE

10. FLANGE HARDENED STEM AND FACE

FLANGE HARDENING EQUIPMENT

11. TEMPER THE INDUCTION HARDENED SHAFT

TFF-04TFF-05TEMPERING FURNACE

SURFACE HARDNESS TEMP OF TEMPERINGTEMPERING PERIOD

12. STRAIGHTENING OF SHAFT STEM

HDP-05BEMCO MAKE HYDRAULIC PRESS

RUNOUT ON 47 INVOLUTE SPLINE DIA

13. GRINDING OF SEAL DIA & FINISHGRINDING OF BEARING DIA & BEARING SEATING FACE

AGR-07ANGULAR HEAD GRINDER

1. SEAL DIA2. BEARING DIA3. SURFACE FINISH ON

BEARING DIA4. DIST OF BEARING

SEATINGFACE FROM FLANGE FRONT

3.45(139JPS)

14. FINISH GRINDING OF SEAL DIA

ANGULAR HEAD GRINDERAGR-05

LENGTH OF SEAL DIASURFACE FINISH OF SEAL DIA

2.91(165 JPS)

15. FINISH GRIND STEM AND FACE

MTC-01FACE GRINDING EQUIPMENTS

1. SURFACE FINISH OF STEM END FACE

2. LENGTH OF STEM END FACE wrt BEARING STEATING FACE

4.21(132 JPS)

16. SUPER FINISH OF SEAL DIA

SFM-02SUFFINA MAKE SUPER FINISHING MACHINE

1. SEAL DIA SURFACE FINISH OF SEAL DIA

2(132 JPS)

16. CHECK CRACK ON REAR AXLE SHAFT

MAGNA FLUX CRACK DETECTOR

1. FREE FROM CRACKS

17. FINAL INSPECTION OF SHAFT REAR AXLE

STAGE 2. AS PER PART PRINT SPECIFICATION

2(132 JPS)

OPERATIONS PERFORMED

FINISH TURN SHAFT REAR AXLE AND CUT THREADS

MACHINE TYPE - NCL-15;NCL-16

CUTTING PARAMETERS:-TOOL NO FEED SPEED06 0.016”/0.20” 750ft/mtr07 0.006”/0.12” 750ft/mtr0101 0.0787/RN 650ft/mtr04 0.012”/RN 700ft/mtr

GAUGE USED

1. G-303272. G-85004/23. G-304054. G-85004/15. G-303296. G-303277. G-303458. G-30343

TESTING SHAFT RUNOUT CHECKING AFTER CNC

OPERATER’S PROCEDURE(BENCH CENTRE)

1. MOUNT THE COMPONENT ON CENTRE2. SHAFT SHOULD BE ALLIGN WITH CENTRE3. CHECK THE SHAFT FOR ROTATION ON THE CENTRES.4. MOUNT THE DIAL GAUGE ON THE TABLE & CHECK THE RUNOUT.5. CHECK THE RUNOUT & IF CHANGE IN DIMENSION, THEN CHECK THE FEED ON THE

MACHINE.

TO DRILL AND REAM 8 BOLT HOLES ON FLANGE

DRILL TWO MANUFACTURING HOLES.

OPERATION GAUGES CHECKING FREQUENCYPOSITION OF 8 HOLES AFTER DRILLING

4235 AAEG 27 1 SHIFT

POSITION OF 8 HOLES AFTER 4235 AAEG 4 1 SHIFT

MILLINGDIA 740”/.760” G-40088 1/50DIA .6675”/.6595(HOLE MILL)

g-40087 1/10

DRILLS USED - 4235AA-ET-85A

HOLE MILLS - 4235AA ET 86A4235AA EG 277235 AA EG 4

LIMIT GAUGES - G-40088 G-40087

OIL GROOVE ON STEM END FACE

CUTTER USED - FM CUTTER 4235 AET 5CUTTING SPEED - 800 RPMFEED - BY HAND

GAUGE TO CHECK 4235 AEG 6

CHAMFER ON 8 HOLES

CHAMFER SIZE - .070+ 0.10”X45

CHECKING FREQUENCY - 1/160

TOOL USED - TS COUNTERSUNK CUTTER DIA 3/4X90”

FINISH MILL 38 & 47 INVOLUTE SPLINES

TOOL & M/C SETTINGS -CUTTER - 4235A ET 83(FOR 47 SPLINE)

REEMER - 4235A-ET 9(FOR 38 SPLINES)FACE CENTRE - 4235AA EF 44/1TAIL STOCK CENTRE - MA-321/25

GAUGES USED - 4235 EG 714235 AEG 294235 AEG 284235 AEG 72

SPEED - 180 RPMFEED - 400M/MIN

SHAFT INDUCTION HARDENING

QUENCH PRESSURE = 5-7.5 Kg/cu.cmQUENCH TEMPERATURE = 25C-45CGAP = 0.085”/.110”

TEMPER INDUCTION HARDENING OF SHAFT

FURNACE TEMPERATURE - 230C-240CTIME PERIOD - 1.5-2.5 HRS

CHARACTERISTICS -CHANGE OF BASE COLOUR TO GOLDEN COLOUR.

GRIND SEAL DIAMETER

GRINDING WHEEL - 4235 AET 87CENTRE - MT-5(2 NOS)DRESSING DIAMOND - MA 902/37

FINISH GRIND SEAL DIAMETER

TAPER CUT GRINDING WHEEL :- 100/68X40X31.75

SUPER FINISH SEAL DIA :- 2.105”/2

STONE USED :- 60mmX60mmX18mm

OSCILATOR DRIVE PRESSURE :- 1.5 – 2.5 BAR.

STAGE INSPECTION

CHECK LIST:-1. 8 NOS BOLT HOLE DIA OF 0.6675”/0.6595”2. SEAL DIA OF 2.100”/2.105”3. SEAL DIA OF 2.6265”/2.6275”4. LENGTH OF 29.096”/29.042”5. 38 SPLINE FOR ALLIGNMENT6. 47 SPLINE FOR ALLIGNMENT7. IF ABOVE COMPONENT IS TIGHT THEN IT IS SENT FOR REWORK.

CRACK CHECKING(MAGNA FLUX)

CURRENT RATING :- 2200-2800 AMPS

IF BLUE LIGHT SHOWS THEN PIECE IS REJECTED OTHERWISE PASSED WITH OK SIGN.

Bibliography

www.google.com www.wikipedia.com www.escortagri.com Text Books Company Production Documents