project report prashant

8/10/2019 Project Report prashant

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ESCORTS AGRI MACHINERY GROUP

INDUSTRIAL PROJECT REPORT

SUBMITTED BY:

NAME:- shaleen

ROLL NO:- 1149240091COLLEGE:- KCC INSTITUTE OF TECHNLOGY ANDMANAGEMENT

BRANCH:- MECHANICAL ENGINEERING


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CONTENTS

ACKNOWLEDGMENT

PREFACE

THE SYMBOL OF ESCORT ESCORTS PROFILE

INTRODUCTION

ESCORTS:RESTRUCTURING

AGRI-MACHINERY GROUP

TRACTOR M/C SHOP(PLANT 1) SHAFT HYDRAULIC LIFT ARM

FACING AND TURNING

ROUGH TURNING

FINISH TURNING

DRILLING

HOBBING ROLLING

WELDING

GRINDING

HARDENING AND TEMPERING

INSPECTION


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ACKNOWLEDGEMENTI would like to thank to all those with whom I worked and whose thoughts and insights

helped me in increasing my knowledge and understanding of working in theorganization .

I would like to pay my sincere gratitude to MR. RAJENDRAYADAV & all employees, my project guide, whohelped me during the course of my training by providing his valuable suggestion, ideas andguidance which proved beneficial for completion of my project . Besides I would also thank to allthe supervisors, Foreman and workers who helped me to understand the depth of my project, whatthey want out of the project.

These people made me comfortable to understand the functioning of each machine &about the operation occuring on the machines. They tried their best to make meunderstand about the fixtures, tools and gauges used on the machine. Thesepeoples never made me feel as a trainee in the department rather provide anatmosphere like a family and feel proud being the part of their through for shortwhile. Without their help this project would never have taken its present form. Infact this project is the result of their vision, optimistic and encouraging attitude .

In the end I would like to thank the ESCORTS AGRI MACHINERYGROUP for providingme with this brilliant opportunity to understand the working of an industry anddeveloping my technical aptitude


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PREFACEIndustrial training now a daysone & the only one method to make

students familiar with the modern techniques, latest equipments &methods used invarious industries. During industrial training , students visit to various companiesand make themselves familiar with the practical aspect of the production method.

This training has provided and ultimate experience& opportunity to have practicalknowledge which has increased my level of thinking and dealing with differentkinds of people in all walks of life. It helps us a lot while appearing to theinterviews. Industrial training in proves the theoretical and the practical conceptof the student about engineering.

The well planned, properly executed & evaluated industrial training helps a lot in inculcating goodwork culture. It provides linkage between the students & the industries in order to developand awareness of industrial approach to problem solving based on broad understanding ofplant.


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THE SYMBOL OF ESCORTSESCORTS symbol holds more than meets the eye graphically. It has been prepared with certain objective in

mind & symbolic in more than one way .

The philosophy behind ESCORTS & ESCORTS symbol is an enterprise.

The hexagon is a symbol of precision when interpreted as a nut; it symbolizes craftsmanship &unendingproductivity. The spanner superimposed the hexagon represent the work and the people of

ESCORTS. This forms the letter E theletter ESCORTS an ever on the move changing invading the future.E - ENSURE INBUILT QUALITYS - SAVING ENERGYC - CALTIVATE SAFE HABITSO - OBSERVE PROCESS NORMSR - REDUCE WASTAGET - TAKE CARE OF MACHINE

S - STRIVE FOR EXCELLENCEThey hopes, aspirations, teamwork and sense of communication help ESCORTS to achieve what it is today, a good reason to

work harder or a still better tomorrow.


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ESCORTS PROFILEEscorts came into being with a vision that was nurtured by MR. HARI NANDA and Late

MR. YUDI NANDA.

The foundation of ESCORTS Limited was laid in the formation of ESCORTS (agents) Ltd. On 17th

October 1944 and of ESCORTS(Agriculture and machines) Ltd. in 1948. These two were later

merged in 1953 to form ESCORTS Agents Pvt. Ltd. The companys

incorporation in its present name ESCORTS Ltd. was effected on 19th January 1960.

Having initially started with a franchise with Westing House domestic appliance, it has come along way in manufacturing and marketing arrange of products. It has pioneered farmmechanization in India through import and distribution of agriculture tractors.

The manufacturing operations commenced in 1954 and since then the following range of new

products has been produced in the country.


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YEAR

1961

1962

1963

1969

1971

1991

1996

1998

1998

PRODUCT

Escorts Tractors

Railway Couplers & Shock

AbsorbersAutomotive Shock Absorbers

Ford Tractors, Now

manufactured under the

FARMTRAC

Industrial & Construction

Equipment

Financial Services

Disengagement of joint venture

with new Holland & launch of

FARMTRAC Tractor

Foundation of Tractor

Transmission Plant (J.V. ca

rraro Grp, Italy)

Foundation of 3rdTractor plant

COMPANY DIVISIONEscorts ltd. (Tractor

Division)

Escorts Railway

Equipments DivisionAutomotive Suspension

Product (Engg. Division)

Escorts Tractors Ltd.

Escorts Construction &

Equipment Ltd.

Escorts Finance Ltd.

Escorts Farmtrac div.

Carraro India Ltd.

Escorts ltd.

LOCATIONFaridabad

Faridabad

Faridabad

Faridabad

Faridabad

Faridabad

Faridabad

Faridabad

Pune


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ESCORTS: RESTRUCTURINGEscorts Limited is all set to face the future by drawing on its 50 years of experience, its inherent strengths

and a strong presence in the core sector providing complementary product line and a vast marketing

network combining them with Indiasintrinsic cost advantages to become a global source point forhigh value engineering products. In order to meet the challenges in the future and to leave anindelible mark on the industrial scenario, Escorts has restructured the group along six business lines,each headed by an independent CEO. The business groups are as follows:-

1. Agri- Machinery Group

2. 2. Construction-Equipment

3. 3. Automotive Ancillaries4. Financial Services

The flag ship of the ESCORTS group is ESCORTS LTD. In the work of MR. RAJAN NANDA, Chairman Escorts Ltd.

In the last 50 years ESCORTS has been more than merely one of the INDIAS largest engineering

companies. It has been a prime mover on the industrial front, at every stage introducing products&technologies that helped to take the country forward in key areas. Today as the nation engagesin its most momentous economic transformation ever, we are once again adapting ourselves towardsbeing catalyst for qualitative growth by engineering change with a global prospective.


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THIS INFRASTRUCTURE COMPRISES:-

23 Main Associates/subsidiary Companies

12 manufacturing Locations

A full-fledged R&D facility

Nearly 10,000 Employees

24 Regional marketing offices

Nearly 500 Sales & Services Outlets

4 Financial Services Companies

Asiasbest training institute of Farm Mechanization with 100 acre

demonstration farm

Escorts Dealer Development Association (EDDAL) Ltd. Providing Management & Financial supports to dealers.


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FT35 :

35 HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,Dry disc brakes, color-blue

FT45 :

42HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission, Drydisc brakes, color-blue

FT50 :

42HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,shoe brakes, color-blue

FT55 :47HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission, Drydisc brakes, color-blue

FT60 :

50HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission, Drydisc brakes, color-blue

FT70 :

60HP Diesel Engine, 3 cylinder, 12+12 partially synchroshuttletransmission, oil immersed

brakes, color-blue


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TRACTOR M/C SHOP (PLANT-1)

The various departments of the Tractor Machine Shop Plant-1 are as follows:

1. Gears and Shafts:The major components manufactured by Gears and Shafts division are:

Engine gears

Transmission Gears and Shafts

Differential Gears and Shafts

Lever

2. Tool Room:The Tool Room caters to jig, fixtures, dies manufacturing etc.

3. Power house:The Power House has generators and compressors of varying capacities.

4. Heavy Castings:The components manufactured by Heavy Castings Division are:

2Cylinder Engine Block

3 Cylinder Engine Block

Gear Box Housing

Differential Housing


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Escorts Plant-3 is engaged in assembly of various models of

Escorts Tractors. It has the following shops:

Engine Assembly Line

Engine Testing

Paint Shop

Transmission Assembly

Main Assembly

Rear Line

Front Line


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Our project is concerning about manufacturing SHAFT HYDRAULIC LIFT ARM

(Serration Shaft).

The various processes involved are:-

1)Facing & Centering

2) Rough Turning

3) Finish Turning

4) Drilling

5) Rolling

6) Hobbing

7) Welding

8) Green grinding

9) Induction hardening

10) Tempering

11) Straightening

12) Hard grinding

13) Hand work

14) Inspection


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Facing & Centering

Facing is part of the turning process. It involves moving the cutting tool at right angles to the axis ofrotation of the rotating work piece. This can be performed by the operation of the cross-slide, ifone is fitted, as distinct from the longitudinal feed (turning). It is frequently the first operationperformed in the production of the work piece, and often the last- hence the phrase "ending up".

This process is used for reducing length and smoothening the face.

Tooling element :-STD Self Centering ViceTGR-F-3951 PADSSwiveling Stopper

Cutting Tool Details :-STD Centre Drill DIA 5/16 inch STD Face Mill Cutter

Speed :-Centre Drill -1000rpmFace Mill Cutter -139rpm

Cutting Time:- 1.5 min

Tool Life:- Centre Drill 500 componentsFace Mill Cutter 100 components

Gauge Details:- STD Height gauge (0-500)TGR-G-9120 Centre Depth Checking Gauge 5.20/5.0


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Rough Turning

When a great deal of stock is to be removed, you should take heavy cuts to complete

the job in the least possible time. This is called rough turning. Select the proper

tool for taking a heavy chip. The speed of the work and the amount of feed of the

tool should be as great as the tool will stand. When you take a roughing cut on

steel, cast iron, or any other metal that has a scale on its surface , be sure to

set the tool deep enough to get under the scale in the first cut. Unless you do, thescale on the metal will dull or break the point of the tool. Rough machine the

work to almost the finished size; then take careful measurements.


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Tooling element:- clamping jaws MAS-317/24

Indexing plate MAS-317/9

Tool holder L-170-5-3225

Tool change frequency:- 200 pcs per edge

Feed :-0.28 mm/rev

Spindle speed :-800 rpm

Gauge details :-STD SNAP gauge 51.000.15

DIAL indicator L.C 0.01


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Finish Turning

When you have rough turned the work to within about 1/32 inch of the finished size, take a finishingcut. A fine feed, the proper lubricant, and, above all, a keen-edged tool is necessary to produce asmooth finish. Measure carefully to be sure you are machining the work to the proper dimension.Stop the lathe when you take measurements if you must finish the work to close tolerances, besure the work is not hot when you take the finish cut. If you turn the work piece to exact size whenit is hot, it will be undersize when it has cooled.

Perhaps the most difficult operation in machine work is to make accurate measurements. So much

depends on the accuracy of the work that you should make every effort to become proficient in theuse of measuring instruments.

Tooling element :-Soft Jaws TGR-F-9114

Cutting Tool Details :STD T-Max Tool Holder PDJNL-2525

Speed :-750rpm

Feed :-0.2mm/min

Cutting Time:- 3.2 minTool Life:- 500 components

Gauge Details:- STD SNAP gauge

DIA 59.69/59.45

Drilling


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Drilling

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials. The drillbit is a multipoint, end cutting tool. It cuts by applying pressure and rotation to the workpiece, which forms chips at the cutting edge.

Machine name :-Radial drill machine

Tooling element :-quick change chuck and sleeve

Cutting tool :-HSS drill dia 11.5 mm

Counter drill dia 13 mm

Tap 20 UNF-2B

Reamer H11

Cutting speed :-HSS drill 580 rpm

Counter drill 300 rpm

Tap 180 rpm

Reamer 180 rpm

Feed :-HSS drill 0.2mm/rev

Counter drill 0.2mm/revGauge Details :-STD Threading gauge

GO , NO GO for 20 UNF-2B thread

Center distance gauge

FTHL-G-9008


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Hobbing

Hobbing uses a hobbing machine with two non-parallel spindles, one mounted with a blank work piece and the otherwith the hob. The angle between the hob's spindle and the work piece's spindle varies ,depending on the type ofproduct being produced. For example, if a spur gear is being produced, then the hob is angled equal to the helixangle of the hob; if a helical gear is being produced then the angle must be increase by the same amount as thehelix angle of the helical gear. The two shafts are rotated at a proportional ratio, which determines the number ofteeth on the blank; for example, if the gear ratio is 40:1 the hob rotates 40 times to each turn of the blank, whichproduces 40 teeth in the blank. Note that the previous example only holds true for a single threaded hob; if thehob has multiple threads then the speed ratio must be multiplied by the number of threads on the hob. The hob isthen fed up into work piece until the correct tooth depth is obtained. Finally the hob is fed into the workpiece

parallel to the blank's axis of rotation .Up to five teeth can be cut into the workpiece at the same time.

Oftentimes multiple gears are cut at the same time.

For larger gears the blank is usually gashed to the rough shape to make hobbing easier

.

Tooling Element :-Job Carrier

Cutting Tool Details :-HOB Cutter

Gauge Details:- OUTSIDE MICROMETER 50-75 mmL.C- 0.01

DIAL indicator L.C 0.01

CONCENTICIT BENCH


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Rolling

Tooling Element :-STD Collet for clamping

ALT. for Hobbing

Cutting Tool Details :-STD Grob Rool

HOB Cutter

Cutting Time:- 2 min

Gauge Details:- Outside Micrometer 50-75mm

Least count - 0.01mm

FTHL-G-9030

Serration Ring Gauge Go


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Welding

The arc welding makes arcs between a material and a welding rod.And it is a well used welding method. In the arc welding, we use a torch with a

welding rod. And both of the material and the welding rod are meant in the arc.

The arc welding is very high speed, and if the welding is very well, the strength is

very high. But the arc is very light, then we cannot see the welding processes. All

weldings, including the arc welding, need higher technique than cutting

processings, because we do not have the same conditions.

i di


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GrindingGrinding practice is a large and diverse area of tool making. It can produce very fine finishes and very accurate

dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. Itis usually better suited to the machining of very hard materials than is "regular" machining (that is, cuttinglarger chips with cuttin tools such as tool bits or milling cutters), and until recent decades it was the onlypractical way to machine such materials as hardened steels. Compared to "regular" machining, itis usually better suited to taking very shallow cuts, such as reducing a shaft's diameter by half a thousandof an inch (thou).(1 thou == 25 um)

Technically, grinding is a subset of cutting, as grinding is a true metal cutting process. Each grain of abrasivefunctions as a microscopic single-point cutting edge (although of high negative rake angle), and shears atiny chip that is analogous to what would conventionally be called a "cut" chip (turning, milling, drilling,tapping, etc.). However, among people who work in the machining fields, the termcuttingIsoftenunderstood to refer to the macroscopic cutting operations, andgrindingis often mentally categorized

as a "separate" process. This is why the terms are usually used in contradistinction in shop-floor practice,even though technically grinding is a subset of cutting.

Tooling element :- Grinding abrasive wheelSpeed :- 39 and 220 rpm

Cutting tool :- Pneumatic grinder


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Hardening & TemperingTempering is a heat treatment technique for metals, alloys and glass. tempering is done to "toughen" the metal by

transforming brittle martensite or bainite into a combination of ferrite and cementite. Precipitation hardeningalloys, like many grades of aluminium and super alloys, are tempered to precipitate inter metallic particles whichstrengthen the metal. Tempering is accomplished by a controlled reheating of the work piece to a temperaturebelow its lower critical temperature.

The brittle martensite becomes tough and ductile after it is tempered. Carbon atoms were trapped in the austenitewhen it was rapidly cooled, typically by oil or water quenching, forming the martensite. The martensite becomesstrong after being tempered because when reheated, the microstructure can rearrange and the carbon atomscan diffuse out of the distorted body-centred-tetragonal (BCT) structure. After the carbon diffuses, the resultis nearly pure ferrite with body-centred structure.

In metallurgy, there is always a trade-off between strength and ductility. Precise control of time and temperatureduring the tempering process are critical to achieve a metal with well balanced mechanical properties.

Power :-220-244 V

Pre-Heating Time :-1.4 sec

Feed Rate :-9mm/sec (53 spline gauge)

Quench dwell time :-32 sec

Speed :-80 rpm


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InspectionINSPECTION IS THE LAST STAGE OF MANUFACTURING.ITIS DONE MANUALLY TO CHECK FOR

DEFECTS AND OTHERIRREGULARITIES.

Gauge details :- SERRATION RING GAUGE

FTHL-G-9030 GO

SERRATION RING GAUGE

FTHL-G-9031 NO GOON MATERIAL 6 SPLINE

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