HMT PPT

PROFESSIONAL TRAINING 1

AT

TRACTOR DIVISION

HINDUSTAN MACHINE TOOLS

Mithun Nehra Roll No-11001004043

B. Tech. Third Year (ME)

Department of Mechanical Engineering, DCR University of Science & Technology, Murthal

Submitted to :- Dr. R K Garg

INTRODUCTION OF COMPANY

1. THE COMPANY WAS STARTED IN 1953 IN BANGALORE.

2. COMPANY CONVERTED INTO PUBLIC LIMITED COMPANY ON MAY 13, 1977.

3. HMT STARTED IN 1963 IN PINJORE.

4. THERE ARE TWO DIVISIONS OF HMT IN PINJORE:-

MACHINE TOOLS DIVISION

TRACTOR DIVISION

PRODUCTS BY HMT TRACTOR

• HMT-2522

• HMT-3522

• HMT-4022

• HMT-4922

• HMT-5022

• HMT-6522

• HMT-7522

WATCHES

TOOLS

The first tractor units produced in HMT Pinjore were named `HMT-ZETRO’Initially Zetro tractors were produced in the unit with the power of 25 BHP

HMT LAYOUTEN

TRY

GuardRoom

TrainingCentre

Boilers And

Condensers

New Heat

Treatmentsection

Tools Section

Light Machine

Shop

TractorWashingSection C

ante

en

FoundryShop

Heavy Machine Shop

TractorAssembl

y

Paint Section

Eng

ine S

hop

Old Heat

Treatment

Shop

STO

RE

New

Engin

e S

hop

TRAINING SCHEDULE TRAINING CENTRE LIGHT MACHINE SHOP NEW ENGINE SHOP FOUNDRY TOOL ROOM ENGINE SHOP HEAT TREATMENT ENGINE ASSEMBLY AND TESTING TRACTOR ASSEMBLY AND TESTING

TRAINING CENTRE

MILING SECTION

MIL

LIN

G

MA

CH

INES Horizontal

Milling Machine

Vertical Milling Machine

Universal Milling Machine

TURNING SECTION

TURNING SECTION HAVE MAINLY LATHE MACHINES

Lathe Machines

Engine Lathe CNC Lathe Trainer

Wood Working

Lathe

Centre Lathe

WHAT WE LEARNT IN TRAINING CENTRE :-

METRIC MICROMETER

VERNIER CALLIPER

Basics of machining like :- > Drilling > Boring > Cutting

Using of 1. Metric Micrometer (LC- 0.01mm) 2. Vernier Calliper (LC – 0.02mm)

Show basic models of :- 1. Engine Parts 2. Powertrain Parts 3. Braking and steering parts 4. Cross section of Full Assembled Tractor

LIGHT MACHINE SHOP

IN THIS SECTION LIGHT PARTS OR SMALL PARTS OF TRACTORS ARE MACHINED SUCH AS :-

SPEED GEARS OF TRACTOR

SUN AND PLANET GEARS

CLUTCH SHAFT

SPLINED SHAFT

GEAR SHIFTING FORK

BEVEL PINION SHAFT

GEAR SHIFTING ROD

STEERING SHAFT

Spline Shaft Gear shifting Fork

Bevel Pinion Shaft

Gear shifting Rod

DIFFERENT MACHINES USED IN LIGHT MACHINE SHOP ARE :-

Gleason

Gear shaping machine

Copying lathe

Cylindrical grinding machine

Broaching Machine

SPLINE SHAFT PRODUCTION PROCEDURE :-

A shaft with longitudinal gear like ridges along its interior or exterior surface is called spline shaft. FunctionThe function of this shaft is to transmit the power from flywheel to the lay shaft Material used: Low carbon steel.

Process for Spline Shaft :-

Raw Material CNC facing turning , Hobbing

Gear hobbing against cutting

gear of 0.05 shaving allowance

HOB = 23

Gear tooth rounding , fitting

and washing

Inspection , Turning ,Bench drilling

BEVEL PINION SHAFT PROCEDURE :-

It is used to transmit the power from gear box to differential. Material used: Low carbon steel.

Raw Material from vendor

Metal cutting > facing > centring

>turning on s-pilot machine

Gear hobbing > Washing > inspection

Work hardening > turning > grinding >

thread rolling > tempering

Shot blasting > washing > inspection

Process for bevel Pinion Shaft :-

NEW ENGINE SHOPIN NEW ENGINE SHOP, MANUFACTURING OF THE ENGINE PARTS IS DONE. THERE ARE TWO MANUFACTURING LINES :-

CRANK CASE LINE

CYLINDER HEAD LINE

Parts machined in New Engine Shop are :- 1. Cylinder head. 2. Crank case. 

1. CYLINDER HEAD :-

Cylinder head contains the inlet valve, exhaust valve fuel injection valve. It is use to cover the cylinder and piston arrangement.

Material used - Cast Iron (CI)

Cylinder Head

Milling of front and bottom on vertical milling

machine

Milling of left and right side on

horizontal milling machine

Valve guide hole on boring machine

Drilling of fuel injection pump

>Reaming of valve guides

Washing and inspection

Process for Cylinder head Production :-

2. CRANKCASE :-

It is the housing for the crank shaft. Material used:- Cast iron (CI).

Crankcase

Material from casting and removal of extra metal

Top face milling on vertical milling machine and

bottom on horizontal milling

machine

Drilling of guide holes > roughing

of liner bores

Drilling of oil filter holes , finishing on

boring machine

Washing and inspection

Process for Crankcase production :-

FOUNDRY SHOPSTEPS OF FOUNDRY MECHANISATION :-

1. Sand preparation.2. Core making.3. Moulding , pouring shakeout.4. Melting.5. Cleaning.

CASTINGS IN FOUNDRY OF HMT :- Gear Box Cylinder Head Rear axle housing

Foundry

Painting & printing section

Testing lab and Fetling section

Melting and metal pouring

section

Core setting section

Sand plant System

Sand handling system

Mould making and handling

Core making and baking

MACHINE AND FURNACE USED IN FOUNDRY :-

Shot Blasting Machine Induction Furnace

STEPWISE PROCEDURE OF CASTING PROCESS IN FOUNDRY :-

Pattern making

Mould making

Metal pouring

Fettling process

Shot blastin

g

Cylinder Head pattern

TOOL ROOM PARTS MANUFACTURING IN TOOL ROOM ARE :-

1. Jigs These are used to hold the jobs on machine2. Fixtures it hold as well as guide the process of machining

Jig Boring Machine

ENGINE SHOPIN ENGINE SHOP THERE ARE TWO MANUFACTURING LINES :-

1. FOR CAM SHAFT

2. FOR CONNECTING ROD

PARTS MANUFACTURED IN ENGINE SHOP ARE :-a. Front & Rear coverb. Camshaft c. Connecting Rodd. Rocker arme. I.G. pinf. Bearing capsg. Oil panh. Tappet pini. Rear axle housing

Camshaft Connecting rod

Bearing cap Tappet pinRocker arm

1. CAMSHAFT :-

A straight, gear-driven shaft that contains lobes used to operate the intake and exhaust valves of a reciprocating engine

Material used: - Alloy steel. Length cutting 327mm

Facing and

centring of shaft

Turning Straightening of

shaft

Bench drilling

of shaft

Key cutting

Fitting of shaft

Grinding for

smoothening

inspection

2. CONNECTING ROD :-

The rod connects the crank shaft of a motor vehicle to the piston

Raw material Surface grinding

Chamfering & Stud holes

drilling

Surface grinding of

cap

Boring of big end & locking

slot cut

Boring of both ends on SPM

Brass bush inserted by hydraulic

press

Inspection

Process for Connecting Rod Production :-

Connecting Rod

HEAT TREATMENTHERE THE COMPONENTS TO BE HEAT TREATED AND QUENCHED IN OIL

Heat Treatment Of CROWN WHEEL :-

Crown wheel

AnnealingHeated to 830-840 ̊̊̊̊c

Quenched in oil bath Washed

Inspection

Fettling is done for :- 1. Surface stress removal 2. Component Cleaning

Fettling is done by Shot Blasting Machine With small steel shots

PROCESS FOR VARIOUS COMPONENTS IN SEALED QUENCHED FURNACE :-

Carburising

At 920̊̊̊c

Fro 2.5 to 5 hrs..

Diffusion

At 920̊

For 1.5 to 2 hrs..

Quenching

At 820̊

15 to 20̊ min

Tempering

at 150̊

For 1.2 to 2 hrs..

Case Depth

0̊.6 to 1.0̊ mm

Hardness Before =

60-64 hrc

After = 58-60 hrc

1. Gears

2. Shafts

Carburising

At 930̊̊̊c

Fro 5 to 7 hrs..

Diffusion

At 930̊

For 2 hrs..

Quenching

At 810̊

15 to 20̊ min

Tempering

at 150̊

For 1.5 to 2 hrs..

Case Depth

0̊.9 to 1.2 mm

Hardness Before =

60-64 hrc

After = 58-60 hrc

3. Crown Wheel

Carburising

At 920̊̊̊c

Fro 3.5 to 5 hrs.

Diffusion

At 920̊

For 2 to 3 hrs.

Gas Cooling

At 760̊ to 820̊

For 1 to 2 hrs.

Case Depth

0̊.85 mm

4. Camshaft

Carburising

At 930̊̊̊c

Fro 8 to 12 hrs.

Diffusion

At 930̊

For 2 to 4 hrs.

Gas Cooling

At 760̊ to 820̊

For 2 hrs.

Case Depth

1.2 mm

ENGINE ASSEMBLYIN THIS SHOP ALL THE ENGINE PARTS OBTAINED FROM THE PREVIOUS SHOPS ARE ASSEMBLED AS TO MAKE THE WHOLE ENGINE AND THEN IN THE TESTING SHOP THE ENGINES ARE TESTED FOR THEIR FITNESS AND GOODNESS FOR DIFFERENT TRACTOR PURPOSES.

ASSEMBLY PROCEDURE :-

Piston Assembly

Crankshaft Assembly

Cam shaft is fitted in crankcase

IPD shaft is fitted

Timing gear fitting

Piston Mounting

Lubrication Pump

assembly

Flywheel Assembly

Water pump fitting

Cylinder head & FIP

is fitted

ENGINE TESTINGEngine Testing Parameters are :- Torque Produced RPM Achieved FUEL Consumption

Run Engine

Check Lubrication Of

rocker Arm

Check Rotation of Push rods

Loading Of Engine

Record Water temp. & oil pressure

Check & Record fuel time and

full load

Check and record

regulated rpm max. & min

Calculate total cycle time

TRACTOR ASSEMBLY

STEPS IN TRACTOR ASSEMBLY :-GEAR BOX ASSEMBLYMTH (MAIN TRANSMISSION HOUSING)DISK BREAK ASSEMBLYREAR AXLE ASSEMBLYCHANNEL PLATE AND TROLLEY HOOK

MOUNTING ENGINE MOUNTING

Gear Box Assembly :-

Gear Box Assembly

Lay Shaft

Splined Shaft

Reduction Shaft Clutch Bended

GearFront Cover

PTO Spline

MT Housing Assembly

• Clean Housing• Mount

Differential kit & Hydraulic Pump

• Assemble Hand Brackets

• Assemble the Pump Shaft And PTO

• Assemble Top cover on gear box

Portal & Direct Axle Mounting

• Assemble differential shaft with two roller bearings

• A bull gear along spring tube

Rear Axle

• Assemble rear axle on MT Housing

• Assemble Brackets

• Assemble Lift • Fill Gear Box

housing with lubricating oil

• Assemble tailor,coupling 7 hinges

Engine Mounting

• Mount Engine on Gear box and MT Housing

Front Axle

• Assemble the front wheel hub, pivot , bush & bearings

• Assemble the front axle bracket

• Then assemble all the parts with tractor body

Steering & Brake Assembly

• Screw and nut type steering assembly is assembled

• Hydraulic Brake Assembly

• 1.Body Master Cylinder

Greasing Zone& Tyre Mounting

• Greasing is done to all parts

• After washing & painting radiator mount on tractor body

Other Parts Assembly :-

Tyre Mounting :-

• TOE in = 4mm• Front distance is constant and from back side distance is increased to 4mm

Alignment

• It provides good balancing of tractor• It prevents from wear and tear of tyres• It helps in steering system

Purpose Of Alignment

THANK YOU