COLLEGE NAME

A TRAINING REPORT AT

HINDUSTAN MACHINE TOOLS (HMT)

PINJORE DIVISION

(FROM JUNE 2nd TO 11th JULY, 2014)

BY Harpreet Singh

12BME1151

ME-02

CONTENTS1.Company Profile

2.Tractor Division

3.Engine Shop

4.Heavy Machine Shop

5.Engine Assembly

6.Heat Treatment

Company ProfileIn 1949 the idea of public sector tools was commissioned to be a corner stone for the government’s industrial development plans. This led to the birth of HINDUSTAN MACHINE TOOLS at Bangalore in 1953 which started a single machine tool factory to produce lathes at Bangalore, in collaboration with M/S Oerlikon of Switzerland.

Next second machine tool unit was set up in Bangalore in 1961 making use of company own resources. Third Machine tool was set up in 1963 at Pinjore, Haryana to produce milling machines

HMT’S tractor business commenced its operation in Pinjore in 1971in technical collaboration with M/S MOTOKOV, Czechoslovakia because priority given to the agriculture in national development programme plan.

HMT started the operation with the manufacture of 25HP tractors. Over the year, it has developed tractor ranging from 25HP to 75HP.

TRACTOR DIVISION• HMT established tractor plant

in Pinjore in 1971to provide impetus to the country’s green revolution. To begin with, it started assembly of 25 HP tractors. Pinjore was selected for the project because it was within the high density crop-producing region which provides immediate market in the vicinity.

• Initially, the tractors were assembled from imported CKD/SKD packs. Production facilities were simultaneously established to reduce the imported contents with the result that the model was fully indigenized within a short span of five years.

• At present, HMT manufactures tractors in 25, 35, 40, 49, 65 and 75 HP ranges. Out of these 35, 40, 49, 65 and 75 HP tractors are designed in-house. All HMT tractors are Bharat term-III certified.

ENGINE SHOPIn engine shop there are manufacturing of the

entire components which is being used in engine assembly. We have seen all the machining process which are used to made a particular component for example cylinder head. Here the following steps used to make cylinder head.

Material comes fro forging section after that following steps done step by step

Surface finish on milling machine(Horizontal Milling Machine for side wise surface finish &vertical for top & bottom)

Drilling of cylinder head on group drilling machine for making inlet & outlet valves.

Injector hole made to hold injector.

Injector hole made in fixture at 20 degree angle.

Final surface finish of cylinder head

inlet & outlet valve on Gun Reaming Machine (Special

Purpose Machine )

HEAVY MACHINE SHOP

It is a part of tractor division in which two types of heavy casting (Gear box and MT housing) are machined and some other components are also manufactured. In this shop the machines are arranged according to the sequence of operation and job moves from one machine to another in series.

The various types of machines present in this shop are:

Semi-Automatic Machines

Radial Drilling Machine

Horizontal Milling Machine

Vertical Milling Machine

Boring Machine

Inclined Boring machine

Thread Milling Machine

Computer Numerical Control(CNC)

Gearbox is that part of tractor which is mounted in the tractor between the Engine and Main Transmission Housing. Speed and Torque of the Tractor as per its operating load condition.

The type of Gearbox used in the tractor is SLIDING MESH GEARBOX. In the Gearbox the Power comes from engine to the clutch shaft and hence to the clutch gear which is always in mesh with a gear on the lay shaft. All the gears on the lay shaft are fixed to it and as such all the time rotating when the engine is running and clutch is engaged. The gears present on the splines shaft are free to slide on it.

Following are the main components of gearbox:

Input Shaft Assembly

Output Shaft Assembly

Lay Shaft Assembly

Intermediate Shaft Assembly

Clutch Actuator guide assembly.Gears.Gearbox Housing Shifter Rods.Shifter Fork.Bearings.Fasteners, gaskets, spacers

POWER TRANSMISSION

Engine(Flywheel) Main Clutch Shaft

1st PTO Hollow Shaft

Spline Shaft(upper) Wavle pin shaft

Reduction Gear(High/Low)

Differential Shaft Crown Wheel

Bull Gear Wheels

ENGINE ASSEMBLY

In this shop, whole of the engine is ready for the tractor assembly; various parts from engine-manufactured section are brought in this section ad they are assembled to prepare the whole engine. The entire engine i.e. 2522, 3522, 5022, 6522 are assembled here. Engine assembly can be divided into 9 no. of steps as follows.

Step 1:-

First of all, the crank housing is washed in a special soap solution because after no. of machining operation it contain drips, cutting oil dust particles, hence washing is necessary. After washing the crank housing is dried by means of air jets.

Step 2:-

Now cylinder sleeves and cylinder lines are fitted in crank housing. The cylinder have groove cut on the external periphery and in the groove a rubber ring is fixed which

Step 4:-

In this step, piston is inserted in the cylinder. Assembly of piston and connecting rod is done repeatedly and then it is put in the cylinder rods big and holes are joined to crankshaft by nuts and bolts. Lubricating gear pump is also assembled and then cam shaft with gear is fixed in camshaft hole present in housing.

Step 5:-

After this fly wheel is mounted on the other end of the crankshaft and inside flywheel, pressure plates and assembled clutch is fixed vices and tightened with the body of the housing.

Step 6:-Mow cylinder head is fixed on the top of the cylinder sleeve by stud cylinder head is assembled in another assembly line. In cylinder head assembly 1st of all its machined casting is thoroughly cleaned and washed. Now in it inlet valve guides, exhaust valve guide with inlet and exhaust valve are fitted, injector with injector holder brush is also fitted in cylinder head valve are pressed tightly against their seat with the help of high tension coiled springs.Step 7:-After fixing the cylinder head on the crank housing, rocker arm, tapped and push rods and assembly fitted for opening and closing of valves.Step 8:-Now the engine is completely assembled by attaching fuel filter, oil filter, fuel injection pump, injection lines, high tension void, starting motor, dynamo etc.

HEAT TREATMENT• Heat treatment shop plays a very important

role in every industry. In automobile industry all the gears and shafts need to be heat treated to impart desired strength and increase life of the component. The H.T. Shop at HMT is equipped with several gas carbonizing furnaces, quenching tanks, induction hardening machines and shot blasting furnaces.

All the treatment processes may be considered to consist of three main parts:

1. The heating of the metal to pre-determined temperature.

2. The Soaking of the metal at that temperature until the structure becomes uniform throughout the mass.

3. The cooling of the metal at some pre-determined rate to cause the formation of desirable structures within the metal/alloy for the desired purposes.

PURPOSES OF THE HEAT TREATMENT:-

Changes in properties result from the micro-structural changes in the material produced by heat treatment operation. However, these serve one or more of the following purposes:

•Improve Machinability.

•Relieve Internal Stresses.

•Improve mechanical properties such as Ductility, Strength, Hardness, Toughness etc.

•Change in Grain Size

Methods of heat treatment:-

Various methods depending upon the nature of Job i.e. it’s material, use etc are employed for giving them heat treatment. The methods used are:

• Annealing

• Normalizing

• Hardening

• Quenching

• Tempering

• Case Hardening

• Carburizing

• Cyaniding

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 throughout 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 throughout the mass.

Main purposes of the Normalizing are:-

• To Remove the effects of previous overheating and thus place the material in good mechanical condition.

• To remove the Internal Stresses caused by cooling from the molten state, by cold working or by rough machining.

• To soften the work prior to further hardening or tempering.

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.

THANK YOU