Crank case manufacturing at pritika industries

Pritika industries limited

Submitted by :Jagmohan Dhiman (2312625)

Naval Gupta (2312642)

Submitted To :

Pritika at a Glance

Pritika started in 1974 by

Mr. R.S.Nibber, a young technocrat,

manufacturing small automotive

components. The company’s products

include machine components, heavy

castings, flywheel housing, crank

case and hydraulic lift cover.

The quality driven organisation

"PRITIKA Group of Industries" is

producing world class components from

modern facilities.

Products at Pritika

It is the leading supplier &

manufacturer of housings and casting

components.

Most of the components which are

manufactured at pritika are made of

Cast iron because it has ultimate

compressive strength and provide

strength to the component.

It is the leading supplier of Hydraulic lift

cover and the engine covers.

The Crank Case manufactured here is

supplied to mahindra tractors. And the

other casting components are supplied to

various renowned companies.

Crank CaseIn an internal combustion engine

of a reciprocating type, the crank

case is the housing for the crank

shaft. A crank case is made up of

Cast iron via sand casting. Besides

protecting the crankshaft

and connecting rods from foreign

objects, the crankcase serves

other functions. It include keeping

the motor oil contained, providing

the rigid structure to the engine

for transmission.

Flow ChartStorage &

inspection

of cast

material

Dowel Hole

Drilling

Pre- machining

( top & side

faces )

Final milling

( top & side

faces)

Multiple

operation on

VMC

Crank side boringCam bore

Gang millingI.G. bore Final inspection

Transportation

Process 1 – Radial Drilling

Here in this first process, the dowel

hole drilling is done. These are the

holes which will help the crank case

to be clamped in further machines.

The one and only purpose of drilling

these holes is to mark those areas

where clamps are fitted and there

will be no wrong clamping.

Dimensions of holes drilled here:

Drill diameter - 14.5 mm

Drill depth - 21 mm

Reamer diameter - 15 mm

Process 2 - Rough Milling

This is the process done in two stages. The first machine is

machining on top & bottom faces and other is on side faces.

The name of machine is Duplex milling machine as the

machining is being done on two faces simultaneously.

Cutter diameter - 400 mm

Feed - 3 mm/min

Process 3 - Final Milling

Here the machine is

again Duplex Milling

Machine. As the process

is final, so, the accuracy

of the machine matters

here. This process is also

done on two stages. The

machine is driven by two

powerful motors.

Cutter diameter - 400 mm

Speed - 500 r.p.m.

Feed - 0.2 mm/min

Process 4 - Vertical Machining

Various processes are being done here which includes : Milling,

Drilling, Boring, Tapping on top side of the Crank Case. This

machine is popularly known as V.M.C. i.e. Vertical Machining

Centre. It is a completely automatic machine in which our work

piece is fixed and tool rotates and moves.

The various operations performed in V.M.C. are as follows :

1. Boring :

• Diameter of boring bar - 123.2 mm• Speed - 400 rpm• Feed Rate - 0.2 mm/min

2. Drilling :

• Diameter of drill - 31 mm• Speed - 650 rpm

3. Milling :

• Diameter of cutter - 100 mm

4. Drilling :

• Diameter of bit - 10.2 mm• Speed - 1000 rpm

5. Tapping :

• Diameter of tapp - 12 mm• Speed - 500 rpm• Feed rate - 0.2 mm/min

Process 5-Boring (Crank Shaft)

Boring is a process of enlarging a hole that already exists. Boring

is done to achieve greater accuracy of the diameter of a hole.

The machine used is Dowel Head Boring Machine.

Diameter of boring bar - 72 mm

Speed - 400 – 650 rpm

Process 6 - Boring(Cam Shaft)

The bore for Cam Shaft is done here and the machine used is

same Dowel Head Boring Machine. The machining of the

component is done on both sides simultaneously. So, the rate is

quite good and efficient.

Diameter of bore - 49 mm

Process 7 – Milling

The machine name is Gang Milling

Machine. As the name suggests

Gang + Milling denotes a group of

milling cutters mounted on the

same arbor in a horizontal milling

set up. All the cutters may

perform same type of operations.

Cutter diameter - 200 mm

Speed - 400 – 600 rpm

Feed rate - 0.2 mm/min

Time Study for Crank CaseThe time observed for operation on different machines during

manufacturing of the Crank Case. A study has been done to

calculate the time consumed by the Crank Case for its

machining is as follows :

• Avg. time for R.D.-20 - 8.04 min

• Avg. time for D.M.M. (pre milling) - 8.26 + 9.55 = 18.35 min

• Avg. time for D.M.M. (final milling) – 10.54 + 8.30 = 19.4min

• Avg. time for V.M.C.- 08 - 15.52 min

• Avg. time for D.H.B.M.- 03 - 6.27 min

• Avg. time for D.H.B.M.- 02 - 8.28 min

• Avg. time for Gang Milling - 6.50 min

• Avg. time for Radial Drill - 1.16 min

So, the total average item taken by all the machines = Time

taken to manufacture a Crank Case after casting is

8.04 + 8.26 + 9.55 + 10.54 + 8.30 + 15.52 + 6.27 + 8.28 +

6.50 + 1.16 = 84.42 minutes.

Hence from the above time study, we have concluded that, A

Crank Case takes 1 hr 24 min for its complete production

process after casting.