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Training report SUBMITTED IN REQUIREMENT FOR SIX MONTH INDUSTRIAL TRAINING At Mahindra & Mahindra, Swaraj division, Chapperchiri. Submitted by: Rajat Kashyap, Roll no: UE99051, B.E. (Mechanical engineering), UIET, Panjab University.
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Swaraj Training Report

Nov 10, 2014

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Rajat Kashyap

Training Report for 6 months training at Mahindra & Mahindra, Swaraj (Tractor Division), Mohali, Plant -I, Chandigarh.
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Page 1: Swaraj Training Report

Training reportSUBMITTED IN REQUIREMENT FOR SIX MONTH INDUSTRIAL TRAINING

At

Mahindra & Mahindra, Swaraj division, Chapperchiri.

Submitted by:Rajat Kashyap,Roll no: UE99051,

B.E. (Mechanical engineering),UIET, Panjab University.

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Contents1. Joining letter2. Preface3. Acknowledgement4. Introduction to company5. Preface to Swaraj6. Swaraj tractor division7. Introduction to various shops and departments:

• Light Machine Shop• Heavy Machine Shop • Assembly Shop• Heat Treatment Shop • Paint Shop • Material Testing Lab • Tool Room • Manufacturing Engg. Deptt. • R & D Deptt • PPC Deptt. • Quality Deptt• Maintainence Deptt.

8. Light machine shop9. Project report10. Conclusion

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2. PrefaceIf you know the laws of buoyancy it doesn’t mean that you know how to swim. It is only through jumping in the water that you get the feel of the depth. This is applicable to every aspect of life. Therefore practical training is of utmost importance. The object of undergoing this training was to get familiar with the weary waters of the industry and to learn how to put theory into practice. I have been greatly privileged to have undergone training at PTL. This report contains the extract of things I learned during my training period.

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3. AcknowledgementAny endeavour cannot lead to success unless and until a proper platform is provided for the same. This is the reason I find myself very fortunate to have undergone my industrial training of four weeks at Panjab Tractors Limited. The persons of my department and all other departments have extended a warm and helping hand.

I am very fortunate to have had a chance to feel the gravity of what role Mechanical Engineering plays in the industry. It was a golden opportunity for me to get a chance to experience what it feels to be in a company where discipline, quality and hard work are the motto. This training helped me a lot in bridging the gap between the theoretical and the practical aspects of my knowledge. First of all I would like to thank Mr. Surjeet Bhullar for his valuable guidance &encouragement as a teacher and a friend throughout my training period.

I am also thankful to Mr. Jajdish Singh for giving me an opportunity to undergo training in such a renowned company. My heartily thanks to Mr. Surjeet Bhullar who was my project manager & my guide through the project works. They always went out of their way to help me at all times. I am sure that the knowledge & information that I have gained during this period would be of immense value for my growth in the field of Mechanical Engineering.

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4. Introduction to companyFounded in 1945 as a steel trading company, we entered automotive manufacturing in 1947 to bring the iconic Willys Jeep onto Indian roads. Over the years, we’ve diversified into many new businesses in order to better meet the needs of our customers. We follow a unique business model of creating empowered companies that enjoy the best of entrepreneurial independence and Group-wide synergies. This principle has led our growth into a US $15.9 billion multinational group with more than 155,000 employees in over 100 countries across the globe. Today, our operations span 18 key industries that form the foundation of every modern economy: aerospace, aftermarket, agribusiness, automotive, components, construction equipment, consulting services, defense, energy, farm equipment, finance and insurance, industrial equipment, information technology, leisure and hospitality, logistics, real estate, retail, and two wheelers. Our federated structure enables each business to chart its own future and simultaneously leverage synergies across the entire Group’s competencies. In this way, the diversity of our expertise allows us to bring our customers the best in many fields.

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5. Preface To SWARAJ

Panjab, the bread basket of India, the land with 50376 sq. Km is situated in Northern part of India. It is agriculturally India’s most advanced and most prosperous state. Panjab

Tractors limited was promoted by PSIDC as one of its projects in 1970 for the manufacturing of agricultural tractors. Since, this gave independence to country from import of tractors, so brand name SWARAJ, total independence was given. SWARAJ tractors conceived in 1965 by a team of dedicated engineers and scientists working at Central mechanical Research Institute, Durgapur with a firm belief that Indian Technology could be brought at par with the best in the world. The first model developed was Swaraj-724 developed over a period of 5 years. Independent commercial production started in the year 1974 and after this company grew by leaps and bounds. Today it is one of the leading tractor manufacturing companies. POSITION OF SWARAJ PRODUCTS IN PRODUCTS IN MARKET:With more than 2 lacs of tractors and harvesters combines operating in Indians farms, SWARAJ are now well-established brand name in the country. SWARAJ is now an internationally recognised name in the developing world. The product of SWARAJ is not restricted to Indian market but they have entered in international market. SWARAJ tractors find an important place in developing countries like Ghana, Tanzania, Kenya, Sudan, Uganda, Indonesia and Malaysia, etc. They are also sending their combines to South Korea having first A.C. cabin in India. Long way back, they had also transported the machined rims to Japan, a project millions of dollars.

SWARAJ – A FASCINATING TALE OF GROWTH:A study of PTL history from project stage to its present position of eminence makes a very interesting reading. It is a fascinating story of inspiration, dedication, perseverance and story will to against all adds and prejudices.

PTL’S BIRTHKeeping in mind Panjab agrarian economy it was decided by Panjab government to encourage the growth of industries which compliments Panjab’s agricultural growth. This task was entrusted to PSIDC that played a major role in bringing Panjab to threshold of industrial revolution. With the dual objective of industrial and agricultural growth, PTL was established on 27 June 1974.

LOCATIONThe factory is located at Chapparchari, the important industrial town of Panjab, 5 km from Chandigarh. The factory was among the first to be set up in this industrial town. The company is managed by board of directors, while the day to day operations are managed by vice-chairman and M.D. of the company.

EXPORT PERFORMANCE OF SWARAJ GROUPSHaving established SWARAJ in the national market, the group made a determined start in the 1980’s to get a foothold in the international market. Over the years a large number of SWARAJ tractors and other implements have been exported to many African countries such as Zambia, Kenya, Tanzania and Nigeria and also in the Middle East and South East Asia. Recently it has exported same engines to U.S.A.

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INTERNATIONAL AND NATIONAL COLLABORATION OF SAWRAJ GROUP• SAWRAJ groups have entered into technical and financial collaboration with various national and international companies.• SAWRAJ Mazda limited was set with technical and financial collaboration with Mazda Motors Corporation of Japan. After the takeover of SAWRAJ by Mahindra and Mahindra group; Mazda has been dissociated from SAWRAJ group.• SAWRAJ combine division was entered into with Komastu Forklift Company of Japan for manufacturing fork lifters.• SAWRAJ engine limited was set up in technical and financial collaboration with Kirloskar Oil Engines Limited, Pune for manufacturing diesel engines.

RESEARCH AND DEVELOPMENT IN SWARAJ GROUPResearch and development is an integral and sustaining department of any organisation, who wants to sustain its place in the emphasis on research and development in the SWARAJ group is proved by a long list of new products that have been introduced and established in the years ever since the established of SWARAJ groupThere is a separate research and development unit of the group located at phase 7 of S.A.S. Nagar (MOHALI). Research work is carried out in this unit and designed work is accomplished. Presently, the research and development is going on with various new products.

VARIOUS COMPANIES OF SWARAJ GROUP• Swaraj tractor division• Swaraj engine division• Swaraj combine division• Swaraj automotive division• Swaraj foundry division

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6. SWARAJ TRACTOR DIVISIONIt is located in phase-4, industrial area, S.A.S. Nagar (Mohali). The construction work of Panjab tractors limited (PTL) started in March 1972 and the first batch rolled out on 14th November 1973. It started with an annual capacity of 5000 tractors with a capital of Rs. 37 million. In 1974 it went into commercial production with SWARAJ 724, 26.5 bhp as its first model. During its 38 years of production, it has not only expanded its manufacturing capacity to more than 24000 tractors per annum but added more products into its manufacturing range.

6.1 SWARAJ COMBINES LIMITEDPanjab tractor limited set up the Swaraj Combine Division (SCD) near ChaperCheri village which is located in TEHSIL – Kharar, DISTRICT – Ropar. It was set up with capital outlay of Rs. 2.6 crores to manufacture self propelled harvesters or combines. In 1985, it also brought out diesel fork lifters of 2 tonnes and 2.5 tonnes lifting capacity. Later on the company entered into technical collaboration with Komatsu Fork Lift, which is a Company of Japan for manufacturing both the diesel and electronic fork lifters of capacity up to 10 tonnes. In April 1995, it has also started production of Swaraj 922 tractors

Fig 6.1 A photo of SWARAJ 8100 HARVESTER COMBINE

6.2 SWARAJ AUTOMOTIVE LIMITED Swaraj automotive limited is situated at Nabha, DISTRICT - Patiala. It was a sick unit before the Swaraj groups over took it. With constant efforts of the new management, now it is again on the path to success. It supplies mudguards and bonnets etc. to the tractor divisions and seats to Maruti.

6.3 SWARAJ FOUNDRY DIVISIONPanjab tractors limited set up a captive foundry unit works with an investment of Rs. 1.50 million in the year 1980 for manufacturing the automotive parts. This foundry division is located at village - Majri in the DISTRICT - Ropar at a distance of about 22 Kms. from

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Chandigarh. Total capacity of this unit is 8000 tonnes of grey cast iron per annum on single shift basis.

6.4 SWARAJ ENGINES LIMITEDSwaraj engines limited (SEL), situated at phase 9, industrial area, Mohali was established in the technical and financial collaboration with Kirloskar oil engines for Swaraj tractor division. The governor of Panjab Mr. S.S. RAY laid the foundation stone of the factory on 29th December 1987. It started production from 28th December 1988. In the first year of production only RV-2 engine were produced. In the second year RV-3 engine were introduced. In the third year two more models R-11 and RV-33 were introduced. In 1999 a new RBB engines has also been introduced. During few years of its existence, it has not only increased its product range but also increased its production from 345 in the first year to more than 18000 engines now.The various engine models produced at SEL are: - 1 RV-2 Two cylinders 24 bhp2 RV-3 Three cylinders 39.5 bhp3 S-15 Single cylinder 25 bhp4 RB-33 Three cylinders 55 bhp5 RB-30 Three cylinders 44 bhp

These engines are sent to the Swaraj tractor division where are fitted on various model tractors. The S-15 engines are manufactured in the Swaraj combine division and are fitted on Swaraj 922 model tractors.

6.5 Popular models of tractors in SWARAJ TRACTOR DIVISION

6.5.1 Swaraj 722 super :Swaraj 722 Super is a 4 stroke, direct injection diesel run tractor with a capacity of 1425cc. The tractor has a water cooled cooling system and comes with 8 forward and 2 reverse speed gears with high and low selector levels. Swaraj 722 super is equipped with self energizing, water sealed disc brakes along with parking brake. The tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel. The vehicle has a shorter turning radius and is very economical in its operation.

Fig. 6.5.1 Swaraj 722 super

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6.5.2 Swaraj 724 FE :Swaraj 724 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 1728cc and has water cooled cooling system. The tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 724 FE is equipped with self energizing, water sealed disc brakes along with parking brake. The tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel. This vehicle is very economical in operations and has a shorter turning radius.

6.5.3 Swaraj 733 FE :Swaraj 733 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2204cc. The tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 733 FE is equipped with self energizing, water sealed disc brakes along with parking brake. The tractor is featured with a single drop arm steering with centrally located horn switch on the steering wheel. This vehicle has a shorter turning radius and is very fuel efficient due to its low diesel consumption.

6.5.4 Swaraj 735 FE :Swaraj 735 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2592cc. The tractor has a water cooled cooling system and has 8 forward and 2 reverse speed gears with high and low selector levels.

Swaraj 735 FE is equipped with self energizing, water sealed disc brakes with parking brake. The tractor further featured with a single drop arm steering with centrally located horn switch on the steering wheel.

Fig. 6.5.2 Swaraj 724 FE

Fig. 6.5.3 Swaraj 733 FE

Fig. 6.5.3 Swaraj 735 FE

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6.5.5 Swaraj 744 :Swaraj 744 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 3136cc. The tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 744 FE is equipped with self energizing, water sealed disc brakes with parking brake. The tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel.

6.5.6 Swaraj 834 FE:Swaraj 834 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2474 cc. The tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 834 FE is equipped with self energizing, water sealed disc brakes along with the parking brake. The tractor is also featured with a single drop arm steering with a centrally located horn switch on the steering wheel.

6.5.7 Swaraj 855:Swaraj 855 is a 4 stroke, direct injection diesel engined tractor ideal for paddy cultivation and suitable for drilling operations with Compressor. This is a 3308cc tractor with 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 855 has a self energizing, water sealed disc brakes with parking brake for extra safety and also has an option of an oil immersed disc brake. The tractor is equipped with a single drop arm steering along with an option of a power steering.

Fig. 6.5.5 Swaraj 744

Fig. 6.5.6 Swaraj 834 FE

Fig. 6.5.7 Swaraj 855

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7. Introduction to various shops and Departments

7.1 LIGHT MACHINE SHOP (L.M.S.) AND HEAVY MACHINE SHOP (H.M.S.):The manufacturing of tractor is performed in various steps. It is manufactured after passing through various processes in various shops. Firstly, various operations on various parts are performed in the L.M.S. and H.M.S. In H.M.S. generally there are four major parts that are given proper machining operations to obtain exact dimension and good surface finish. These include gear box casing, brake hodge, differential housing, trumpet housing and rear cover. Similarly, in L.M.S. the light parts are produced and proper machining is given to them. The various parts include gears, shafts, cage assembly casing etc.

All heavy castings of tractor are machined in this shop with the help of variety of Special Purpose Machines (SPM). These machines are tailors made by IIMT to suit component requirements. In addition, facilities of this shop include general purpose turning, drilling and milling machines. About 20 special purpose machines and 30 general purpose machines are installed in a covered area of 47000 sq. Ft. At least a cost of 20 million, 2600 tonnes of castings is machined every year on a two shift basis. In addition to the machining of casting for the tractor, some jobs are also performed for Swaraj Mazda Limited.

7.1.1 COMPONENTS MACHINED IN THIS SHOP: -1. Gear box housing2. Differential housing3. Rear cover4. Trumpet housing5. Brake hodge

THE PLANT

PRODUCTION

•L.M.S

•H.M.S

•HEATTREATMENT

•ASEEMBLY&

•PAINTSHOP

•V.D.C.

•TOOLROOM

•R&D

•P.P.C.

•QUALITY

•PURCHACE

•MANG.SYS.

•FINANCE

•MARKETING

•H.R.D.

PRODUCT SUPPORT

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7.2 HEAT TREATMENT SHOPIn heat treatment shop, the light parts which are made in L.M.S such as gears, shafts are given the heat treatment to ensure their strength. Firstly the parts after passing through various operations in L.M.S. are taken to the heat treatment shop. Here the part is kept in the furnace for suitable time period up to certain high temperature. Then it is taken to the quenching tank where the hot parts are dipped in the oil. After that the parts are taken to washing tank for washing the parts so that the dirt and oil removed from the parts. Then the treated parts are taken to assembly line.

7.3 ASSEMBLY AND PAINT SHOPIn assembly line various parts are being assembled into a single unit termed as “tractor”. During assembly the various parts are being fitted according to the stage. This would include the assembly of important parts such as rear cover, cover, gear box, differential housing and trumpet housing.

Firstly the various sub-parts of the rear cover are being fitted into the gear box. After that both the rear cover and the gear box are taken to the line where the various things such as brakes, P.T.O. shaft, cage assembly, trumpet housing etc. are fitted to the differential housing. Then this whole assembly is fitted with the engine against the gear box. After whole assembly is fitted with the engine, this assembly is taken to the Chassis paint area, where it is washed and dry followed by paint on the chassis.

Then the tractor reaches to the final stage where certain electrical and other accessories such as battery cover, steering wheel, radiator etc are fitted. Proper level of engine oil is also filled into the differential and gear box. Greasing of various parts is also performed with grease gun. After that the tractor is taken out of the line after taken it out from the hooks. This stage is termed as dismounting stage. Then the testing of the tractor is performed which include the checking for vibrations, noise, brakes, oil level and other factors that effects the performance of tractor.

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8. LIGHT MACHINE SHOPL.M.S. is the largest section of the factory. All transmission components like shafts and gears used tractor are manufactured here. L.M.S comprises of 70 machines, out of which 29 C.N.C. (Computer Numerical Control) machines. Except the bevel gear generator and gear shaver, which have been imported W.M.W. and Churchill (Germany) respectively and all other machines is from H.M.T. Ltd. 160 highly experienced operators and inspectors are working in this shop.

8.1 VARIOUS PROCESSES PERFORMED IN L.M.S. :

8.1.1 Grinding: Grinding practice is a large and diverse area of manufacturing and toolmaking. 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. It is usually better suited to the machining of very hard materials than is “regular” machining (that is, cutting larger chips with cutting tools such as tool bits or milling cutters), and until recent decades it was the only practical way to machine such materials as hardened steels. Compared to “regular” machining, it is usually better suited to taking very shallow cuts, such as reducing a shaft’s diameter by half a thousandth of an inch (thou) or 12.7 um.

Fig. 8.1 LMS Layout

Fig. 8.1.1 Aluminium Oxide abrasive, Bore gauge, Grinding machine

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Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny 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 term cutting is often understood to refer to the macroscopic cutting operations, and grinding is often mentally categorized as a “separate” process. This is why the terms are usually used in contradistinction in shop-floor practice, even though, strictly speaking, grinding is a subset of cutting.

8.1.1.1 Various grades of grinding wheel abrasive are :• A (Aluminium Oxide)• C (Silicon Carbide)• Z (Zirconia)

8.1.1.2 Various types of grinding in L.M.S. :

A. Cylindrical Grinding: Cylindrical grinding (also called center-type grinding) is used in the removing the cylindrical surfaces and shoulders of the workpiece. The workpiece is mounted and rotated by a workpiece holder, also known as a grinding dog or center driver. Both the tool and the workpiece are rotated by separate motors and at different speeds. The axes of rotation tool can be adjusted to produce a variety of shapes. The five types of cylindrical grinding are: outside diameter (OD) grinding, inside diameter (ID) grinding, plunge grinding, creep feed grinding, and centerless grinding.

Jobs : drive shaft, bevel pinion, B.P.S. (left), B.P.S. (right), bevel wheel.

B. Internal Grinding: Internal grinding is used to grind the internal diameter of the workpiece. Tapered holes can be ground with the use of internal grinders that can swivel on the horizontal.

Jobs : drive shaft, bevel pinion, input shaft.

8.1.2 Hobbing: Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting

Fig. 8.1.2 B.P. Shaft (finished and unfinished), B.P. shaft mounted in machine

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process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.Modern hobbing machines, also known as hobbers, are fully automated machines that come in many sizes, because they need to be able to produce anything from tiny instrument gears up to 10 ft (3.0 m) diameter marine gears. Each gear hobbing machine typically consists of a chuck and tailstock, to hold the workpiece or a spindle, a spindle on which the hob is mounted, and a drive motor.

Jobs: Input shaft, gear Z-32, CM gear.

8.1.3 Gear Shaper: A gear shaper is a machine tool for cutting the teeth of internal or external gears. The name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away from the part on the return stroke, just like the clapper box on a planer shaper. The cutting tool is also gear shaped having the same pitch as the gear to be cut. However number of cutting teeth must be less than that of the gear to be cut for internal

Fig. 8.1.2 Helical gear and simple gear being hobbed

Fig. 8.1.3 finished gears, gear shaper in action.

Fig. 8.1.2 bevel gear forming

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gears. For external gears the number of teeth on the cutter is limited only by the size of the shaping machine. Jobs: Internal gears.

8.1.4 Vertical Milling: In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill. Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down requires considerable effort and it also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines are usually of the bed type.

Jobs: Planet carrier.

8.1.5 Drilling : Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the workpiece, cutting off chips from what will become the hole being drilled.

Fig. 8.1.4 Vertical Milling machine

Fig. 8.1.5 drilled component, non-drilled component, various drills and Vertical Milling machine

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8.1.6 Deburring : A burr is a raised edge or small pieces of material remaining attached to a workpiece after a modification process. It is usually an unwanted piece of material and when removed with a deburring tool in a process called ‘deburring’. Burrs are most commonly created after machining operations, such as grinding, drilling, milling, engraving or turning. It may be present in the form of a fine wire on the edge of a freshly sharpened tool or as a raised portion of a surface; this type of burr is commonly formed when a hammer strikes a surface. Deburring accounts for a significant portion of manufacturing costs.

There are many deburring processes, but the most common are mass-finishing, spindle finishing, media blasting, sanding, grinding, wire brushing, abrasive flow machining, electrochemical deburring, electropolishing, thermal energy method, machining, and manual deburring. Manual deburring is the most common deburring process because it is the most flexible process. It also only requires low cost tools and allows for instant inspection.

8.1.7 Broaching: Broaching is a machining process that uses a toothed tool, called a broach, to remove material. Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semi-finishing, and the final one for finishing. Broaching is an unusual machining process because it has the feed built into the tool. The profile of the machined surface is always the inverse of the profile of the broach. The rise per tooth (RPT), also known as the step or feed per tooth, determines the amount of material removed and the size of the chip. The broach can be moved relative to the workpiece or vice-versa. Because all of the features are built into the broach no complex motion or skilled labor is required to use it.

Fig. 8.1.6 Gear before and after deburring.

Fig. 8.1.7 Broaching machine and internal teeth formed through broaching in an internal gear.

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8.1.8 Boring: In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by means of a single-point cutting tool (or of a boring head containing several such tools), for example as in boring a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning, which cuts external diameters.

Fig. 8.1.8 Boring Machine

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9. Training Report

AIM : To eliminate unsafe condition at de-burring machine

Define the problem:To improve safety on M/C 665.02, during the operation of de-burring lots of chips of particle size are created which scatter everywhere. This causes safety hazard to the operator and also it leads to bad housekeeping.

Analysis of the problem:

What?Bad housekeeping and safety problem at M/C 665.02.

Where?M/C 665.02

When?De-burring regular procedure.

Who?Because of production process by which de-burring is done.

How?Using QC tools and technique.

Classification of causes1. Problem in process (process not correct)2. De-burring wheel not ok.3. Process done by operator not correct.4. No provision for avoiding dust.5. Table symmetry not ok.6. Operator not wearing PPE.7. Scattering of dust being caused due to some internal agent.

The vital cause was analyzed by WHY-WHY analysis:

The problem is that there is no proper way for chips to get away.

No provision for chips to get out of process in a regular way.

No cover or sink is there that collects the chips and removes them from the place properly.

It is dangerous for the operator in operating time.

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Developing solution:1. To use the chips collecting dust cover2. Goggles to be given to the operator.3. Gloves to be given to the operator.

Decided solution:A chips dust cover is used to store the chips to the back side in the direction of chips and goggles and gloves are provided.

MACHINE MAN

METHOD METERIAL

TABLE SYMMETRY NOT OKAY

PROBLEMS IN PROCESS

DEBURRING WHEEL NOT OKAY

NO PROVISIONS FOR DEVIATING DUST

SCATTERING OF DUST BURR CAUSED DUE TO SOME

EXTERNAL AGENTS

TO IMPROVE SAFETY&

HOUSEKEEPING

APPROACH OF OPERATOR NOT CORRECT

OPERATOR NOT WEARING PPE

Fig. 9.1 Fishbone diagram

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S/N MACHINE NAME MACHINE NO. LEAKAGE

1CNC Turning (twin

chucker)

196.01 Pneumatic leakage from left side auto-door

196.03 Leakage in axis motor (left) and spindle motor (both)

196.04 Leakage from hydraulic unit

2 Shaper 614.01 Hydraulic oil leakage from motor of hyd. unit

3 Internal gear shaper 615.01 Cutting oil leakage from T-joint

4 Hobbing

624.06Hydraulic oil mixes with cutting oil

624.07

624.14 Hydraulic oil leakage from unit (Joints)

624.05 Hydraulic oil leakage from tank

5 Gear tooth rounding 667.01 Hydraulic oil leakage from unit

6 Broaching 354.01Leakage from Hydraulic unit (approx. 10 Joints), DC Valve & Flow control

valve

7 Vertical Milling 497.01 Hydraulic oil leakage (Minor)

8 Bevel Generator 645.04Hydraulic oil leakage from; hydraulic unit (joints), bottom of machine and

feed gear box

9 Bevel Pinion Generator 645.03 Hydraulic oil leakage in feed gear box

10 Bevel Wheel Generator 645.02 Hydraulic oil leakage from; hyd. unit & bottom of machine

11 Cylindrical Grinding 523.03 Leakage in magnetic separator motor & hyd. unit

12 Bevel Wheel Grinding 536.03 Hydraulic oil leakage from hyd. unit (joints)

13 CNC Internal Grinding

554.01Air leakage from air pipe (tape has been applied); Hydraulic oil leakage from

workhead (from backside) due to improper sealing

554.03Pneumatic leakage (air inlet pipe’s valve handle); hydraulic oil leakage

(pressure regulator joint of hyd. unit)

554.02 Pneumatic leakage (minor); coolant leakage from coolant motor

554.05 Hydraulic oil leakage from hyd. tank

14CNC Cylindrical

Grinding

538.01 Lubrication oil leakage from lubrication oil motor

538.02Coolant leakage from coolant motor; pressure gauge oil leakage; hyd. oil

leakage from hyd. unit; minor oil leakage from lubrication unit

15 Cylindrical Grinding

535.01Hydraulic oil leakage from wheel head motor; Hydraulic oil leakage from under the table base; Hydraulic oil leakage fro machine front base (circuit

panel)

535.02Leakage in magnetic separator motor (lubrication oil); Hydraulic oil leakage from machine front; coolant leakage above coolant spray; Hydraulic oil

leakage in wheel head motor

535.03 Hydraulic oil leakage from hyd. tank; coolant leakage

16 CNC Turning 166.05 Hydraulic oil leakage

17 Milling 497.03 Hydraulic oil leakage from hyd. motor; coolant leakage from chip conveyor

18 Radial drilling 437.13 Hydraulic oil leakage from electrical unit

19 4-Way Boring 482.01Pneumatic leakage from supply pipe; Hydraulic oil leakage from hyd. unit

oil pump

20 Cylindrical Grinding

537.01

Hydraulic oil leakage from lever joint537.02

21 Gear tooth rounding 668.03 Cutting oil leakage

CHECK ING FOR LEAKAGES IN L .M.S MACHINES

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10. Conclusion of trainingMy training was the most versatile experience. I had the pleasure to do the work with one of the most reputed factory in their field-“PANJAB TRACTORS LTD.” I received the blend of experience in Private as well as in Govt. sector. It was a good learning time during my training as we were fortunate to be placed in the department related to manufacturing. I feel training has give me exposure to undergo projects in the Manufacturing field as well help me a lot to understand the company work culture, working with teams and much more. In the end I will like to thank all persons who helped me throughout my training to enhance my experience. I also pay my regards to my Lecturers for their guidance during my training and my Academics helped me to do a lot during my training.

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Contents1. Joining letter2. Preface3. Acknowledgement4. Introduction to company5. Preface to Swaraj6. Swaraj tractor division7. Introduction to various shops and departments:

• Light Machine Shop• Heavy Machine Shop • Assembly Shop• Heat Treatment Shop • Paint Shop • Material Testing Lab • Tool Room • Manufacturing Engg. Deptt. • R & D Deptt • PPC Deptt. • Quality Deptt• Maintainence Deptt.

8. Light machine shop9. Project report10. Conclusion

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2. PrefaceIf you know the laws of buoyancy it doesn’t mean that you know how to swim. It is only through jumping in the water that you get the feel of the depth. �is is applicable to every aspect of life. �erefore practical training is of utmost importance. �e object of undergoing this training was to get familiar with the weary waters of the industry and to learn how to put theory into practice. I have been greatly privileged to have undergone training at PTL. �is report contains the extract of things I learned during my training period.

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3. AcknowledgementAny endeavour cannot lead to success unless and until a proper platform is provided for the same. �is is the reason I �nd myself very fortunate to have undergone my industrial training of four weeks at Panjab Tractors Limited. �e persons of my department and all other departments have extended a warm and helping hand.

I am very fortunate to have had a chance to feel the gravity of what role Mechanical Engineering plays in the industry. It was a golden opportunity for me to get a chance to experience what it feels to be in a company where discipline, quality and hard work are the motto. �is training helped me a lot in bridging the gap between the theoretical and the practical aspects of my knowledge. First of all I would like to thank Mr. Surjeet Bhullar for his valuable guidance &encouragement as a teacher and a friend throughout my training period.

I am also thankful to Mr. Jajdish Singh for giving me an opportunity to undergo training in such a renowned company. My heartily thanks to Mr. Surjeet Bhullar who was my project manager & my guide through the project works. �ey always went out of their way to help me at all times. I am sure that the knowledge & information that I have gained during this period would be of immense value for my growth in the �eld of Mechanical Engineering.

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4. Introduction to companyFounded in 1945 as a steel trading company, we entered automotive manufacturing in 1947 to bring the iconic Willys Jeep onto Indian roads. Over the years, we’ve diversi�ed into many new businesses in order to better meet the needs of our customers. We follow a unique business model of creating empowered companies that enjoy the best of entrepreneurial independence and Group-wide synergies. �is principle has led our growth into a US $15.9 billion multinational group with more than 155,000 employees in over 100 countries across the globe. Today, our operations span 18 key industries that form the foundation of every modern economy: aerospace, a�ermarket, agribusiness, automotive, components, construction equipment, consulting services, defense, energy, farm equipment, �nance and insurance, industrial equipment, information technology, leisure and hospitality, logistics, real estate, retail, and two wheelers. Our federated structure enables each business to chart its own future and simultaneously leverage synergies across the entire Group’s competencies. In this way, the diversity of our expertise allows us to bring our customers the best in many �elds.

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5. Preface To SWARAJ

Panjab, the bread basket of India, the land with 50376 sq. Km is situated in Northern part of India. It is agriculturally India’s most advanced and most prosperous state. Panjab

Tractors limited was promoted by PSIDC as one of its projects in 1970 for the manufacturing of agricultural tractors. Since, this gave independence to country from import of tractors, so brand name SWARAJ, total independence was given. SWARAJ tractors conceived in 1965 by a team of dedicated engineers and scientists working at Central mechanical Research Institute, Durgapur with a �rm belief that Indian Technology could be brought at par with the best in the world. �e �rst model developed was Swaraj-724 developed over a period of 5 years. Independent commercial production started in the year 1974 and a�er this company grew by leaps and bounds. Today it is one of the leading tractor manufacturing companies. POSITION OF SWARAJ PRODUCTS IN PRODUCTS IN MARKET:With more than 2 lacs of tractors and harvesters combines operating in Indians farms, SWARAJ are now well-established brand name in the country. SWARAJ is now an internationally recognised name in the developing world. �e product of SWARAJ is not restricted to Indian market but they have entered in international market. SWARAJ tractors �nd an important place in developing countries like Ghana, Tanzania, Kenya, Sudan, Uganda, Indonesia and Malaysia, etc. �ey are also sending their combines to South Korea having �rst A.C. cabin in India. Long way back, they had also transported the machined rims to Japan, a project millions of dollars.

SWARAJ – A FASCINATING TALE OF GROWTH:A study of PTL history from project stage to its present position of eminence makes a very interesting reading. It is a fascinating story of inspiration, dedication, perseverance and story will to against all adds and prejudices.

PTL’S BIRTHKeeping in mind Panjab agrarian economy it was decided by Panjab government to encourage the growth of industries which compliments Panjab’s agricultural growth. �is task was entrusted to PSIDC that played a major role in bringing Panjab to threshold of industrial revolution. With the dual objective of industrial and agricultural growth, PTL was established on 27 June 1974.

LOCATION�e factory is located at Chapparchari, the important industrial town of Panjab, 5 km from Chandigarh. �e factory was among the �rst to be set up in this industrial town. �e company is managed by board of directors, while the day to day operations are managed by vice-chairman and M.D. of the company.

EXPORT PERFORMANCE OF SWARAJ GROUPSHaving established SWARAJ in the national market, the group made a determined start in the 1980’s to get a foothold in the international market. Over the years a large number of SWARAJ tractors and other implements have been exported to many African countries such as Zambia, Kenya, Tanzania and Nigeria and also in the Middle East and South East Asia. Recently it has exported same engines to U.S.A.

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INTERNATIONAL AND NATIONAL COLLABORATION OF SAWRAJ GROUP• SAWRAJ groups have entered into technical and �nancial collaboration with various national and international companies.• SAWRAJ Mazda limited was set with technical and �nancial collaboration with Mazda Motors Corporation of Japan. A�er the takeover of SAWRAJ by Mahindra and Mahindra group; Mazda has been dissociated from SAWRAJ group.• SAWRAJ combine division was entered into with Komastu Forkli� Company of Japan for manufacturing fork li�ers.• SAWRAJ engine limited was set up in technical and �nancial collaboration with Kirloskar Oil Engines Limited, Pune for manufacturing diesel engines.

RESEARCH AND DEVELOPMENT IN SWARAJ GROUPResearch and development is an integral and sustaining department of any organisation, who wants to sustain its place in the emphasis on research and development in the SWARAJ group is proved by a long list of new products that have been introduced and established in the years ever since the established of SWARAJ group�ere is a separate research and development unit of the group located at phase 7 of S.A.S. Nagar (MOHALI). Research work is carried out in this unit and designed work is accomplished. Presently, the research and development is going on with various new products.

VARIOUS COMPANIES OF SWARAJ GROUP• Swaraj tractor division• Swaraj engine division• Swaraj combine division• Swaraj automotive division• Swaraj foundry division

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6. SWARAJ TRACTOR DIVISIONIt is located in phase-4, industrial area, S.A.S. Nagar (Mohali). �e construction work of Panjab tractors limited (PTL) started in March 1972 and the �rst batch rolled out on 14th November 1973. It started with an annual capacity of 5000 tractors with a capital of Rs. 37 million. In 1974 it went into commercial production with SWARAJ 724, 26.5 bhp as its �rst model. During its 38 years of production, it has not only expanded its manufacturing capacity to more than 24000 tractors per annum but added more products into its manufacturing range.

6.1 SWARAJ COMBINES LIMITEDPanjab tractor limited set up the Swaraj Combine Division (SCD) near ChaperCheri village which is located in TEHSIL – Kharar, DISTRICT – Ropar. It was set up with capital outlay of Rs. 2.6 crores to manufacture self propelled harvesters or combines. In 1985, it also brought out diesel fork li�ers of 2 tonnes and 2.5 tonnes li�ing capacity. Later on the company entered into technical collaboration with Komatsu Fork Li�, which is a Company of Japan for manufacturing both the diesel and electronic fork li�ers of capacity up to 10 tonnes. In April 1995, it has also started production of Swaraj 922 tractors

Fig 6.1 A photo of SWARAJ 8100 HARVESTER COMBINE

6.2 SWARAJ AUTOMOTIVE LIMITED Swaraj automotive limited is situated at Nabha, DISTRICT - Patiala. It was a sick unit before the Swaraj groups over took it. With constant e�orts of the new management, now it is again on the path to success. It supplies mudguards and bonnets etc. to the tractor divisions and seats to Maruti.

6.3 SWARAJ FOUNDRY DIVISIONPanjab tractors limited set up a captive foundry unit works with an investment of Rs. 1.50 million in the year 1980 for manufacturing the automotive parts. �is foundry division is located at village - Majri in the DISTRICT - Ropar at a distance of about 22 Kms. from

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Chandigarh. Total capacity of this unit is 8000 tonnes of grey cast iron per annum on single shi� basis.

6.4 SWARAJ ENGINES LIMITEDSwaraj engines limited (SEL), situated at phase 9, industrial area, Mohali was established in the technical and �nancial collaboration with Kirloskar oil engines for Swaraj tractor division. �e governor of Panjab Mr. S.S. RAY laid the foundation stone of the factory on 29th December 1987. It started production from 28th December 1988. In the �rst year of production only RV-2 engine were produced. In the second year RV-3 engine were introduced. In the third year two more models R-11 and RV-33 were introduced. In 1999 a new RBB engines has also been introduced. During few years of its existence, it has not only increased its product range but also increased its production from 345 in the �rst year to more than 18000 engines now.�e various engine models produced at SEL are: - 1 RV-2 Two cylinders 24 bhp2 RV-3 �ree cylinders 39.5 bhp3 S-15 Single cylinder 25 bhp4 RB-33 �ree cylinders 55 bhp5 RB-30 �ree cylinders 44 bhp

�ese engines are sent to the Swaraj tractor division where are �tted on various model tractors. �e S-15 engines are manufactured in the Swaraj combine division and are �tted on Swaraj 922 model tractors.

6.5 Popular models of tractors in SWARAJ TRACTOR DIVISION

6.5.1 Swaraj 722 super :Swaraj 722 Super is a 4 stroke, direct injection diesel run tractor with a capacity of 1425cc. �e tractor has a water cooled cooling system and comes with 8 forward and 2 reverse speed gears with high and low selector levels. Swaraj 722 super is equipped with self energizing, water sealed disc brakes along with parking brake. �e tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel. �e vehicle has a shorter turning radius and is very economical in its operation.

Fig. 6.5.1 Swaraj 722 super

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6.5.2 Swaraj 724 FE :Swaraj 724 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 1728cc and has water cooled cooling system. �e tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 724 FE is equipped with self energizing, water sealed disc brakes along with parking brake. �e tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel. �is vehicle is very economical in operations and has a shorter turning radius.

6.5.3 Swaraj 733 FE :Swaraj 733 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2204cc. �e tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 733 FE is equipped with self energizing, water sealed disc brakes along with parking brake. �e tractor is featured with a single drop arm steering with centrally located horn switch on the steering wheel. �is vehicle has a shorter turning radius and is very fuel e�cient due to its low diesel consumption.

6.5.4 Swaraj 735 FE :Swaraj 735 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2592cc. �e tractor has a water cooled cooling system and has 8 forward and 2 reverse speed gears with high and low selector levels.

Swaraj 735 FE is equipped with self energizing, water sealed disc brakes with parking brake. �e tractor further featured with a single drop arm steering with centrally located horn switch on the steering wheel.

Fig. 6.5.2 Swaraj 724 FE

Fig. 6.5.3 Swaraj 733 FE

Fig. 6.5.3 Swaraj 735 FE

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6.5.5 Swaraj 744 :Swaraj 744 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 3136cc. �e tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 744 FE is equipped with self energizing, water sealed disc brakes with parking brake. �e tractor is featured with a single drop arm steering with a centrally located horn switch on the steering wheel.

6.5.6 Swaraj 834 FE:Swaraj 834 FE is a 4 stroke, direct injection diesel run tractor with a capacity of 2474 cc. �e tractor has 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 834 FE is equipped with self energizing, water sealed disc brakes along with the parking brake. �e tractor is also featured with a single drop arm steering with a centrally located horn switch on the steering wheel.

6.5.7 Swaraj 855:Swaraj 855 is a 4 stroke, direct injection diesel engined tractor ideal for paddy cultivation and suitable for drilling operations with Compressor. �is is a 3308cc tractor with 8 forward and 2 reverse speed gears with high and low selector levels.Swaraj 855 has a self energizing, water sealed disc brakes with parking brake for extra safety and also has an option of an oil immersed disc brake. �e tractor is equipped with a single drop arm steering along with an option of a power steering.

Fig. 6.5.5 Swaraj 744

Fig. 6.5.6 Swaraj 834 FE

Fig. 6.5.7 Swaraj 855

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7. Introduction to various shops and Departments

7.1 LIGHT MACHINE SHOP (L.M.S.) AND HEAVY MACHINE SHOP (H.M.S.):�e manufacturing of tractor is performed in various steps. It is manufactured a�er passing through various processes in various shops. Firstly, various operations on various parts are performed in the L.M.S. and H.M.S. In H.M.S. generally there are four major parts that are given proper machining operations to obtain exact dimension and good surface �nish. �ese include gear box casing, brake hodge, di�erential housing, trumpet housing and rear cover. Similarly, in L.M.S. the light parts are produced and proper machining is given to them. �e various parts include gears, sha�s, cage assembly casing etc.

All heavy castings of tractor are machined in this shop with the help of variety of Special Purpose Machines (SPM). �ese machines are tailors made by IIMT to suit component requirements. In addition, facilities of this shop include general purpose turning, drilling and milling machines. About 20 special purpose machines and 30 general purpose machines are installed in a covered area of 47000 sq. Ft. At least a cost of 20 million, 2600 tonnes of castings is machined every year on a two shi� basis. In addition to the machining of casting for the tractor, some jobs are also performed for Swaraj Mazda Limited.

7.1.1 COMPONENTS MACHINED IN THIS SHOP: -1. Gear box housing2. Di�erential housing3. Rear cover4. Trumpet housing5. Brake hodge

THE PLANT

PRODUCTION

•L.M.S

•H.M.S

•HEATTREATMENT

•ASEEMBLY&

•PAINTSHOP

•V.D.C.

•TOOLROOM

•R&D

•P.P.C.

•QUALITY

•PURCHACE

•MANG.SYS.

•FINANCE

•MARKETING

•H.R.D.

PRODUCT SUPPORT

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7.2 HEAT TREATMENT SHOPIn heat treatment shop, the light parts which are made in L.M.S such as gears, sha�s are given the heat treatment to ensure their strength. Firstly the parts a�er passing through various operations in L.M.S. are taken to the heat treatment shop. Here the part is kept in the furnace for suitable time period up to certain high temperature. �en it is taken to the quenching tank where the hot parts are dipped in the oil. A�er that the parts are taken to washing tank for washing the parts so that the dirt and oil removed from the parts. �en the treated parts are taken to assembly line.

7.3 ASSEMBLY AND PAINT SHOPIn assembly line various parts are being assembled into a single unit termed as “tractor”. During assembly the various parts are being �tted according to the stage. �is would include the assembly of important parts such as rear cover, cover, gear box, di�erential housing and trumpet housing.

Firstly the various sub-parts of the rear cover are being �tted into the gear box. A�er that both the rear cover and the gear box are taken to the line where the various things such as brakes, P.T.O. sha�, cage assembly, trumpet housing etc. are �tted to the di�erential housing. �en this whole assembly is �tted with the engine against the gear box. A�er whole assembly is �tted with the engine, this assembly is taken to the Chassis paint area, where it is washed and dry followed by paint on the chassis.

�en the tractor reaches to the �nal stage where certain electrical and other accessories such as battery cover, steering wheel, radiator etc are �tted. Proper level of engine oil is also �lled into the di�erential and gear box. Greasing of various parts is also performed with grease gun. A�er that the tractor is taken out of the line a�er taken it out from the hooks. �is stage is termed as dismounting stage. �en the testing of the tractor is performed which include the checking for vibrations, noise, brakes, oil level and other factors that e�ects the performance of tractor.

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8. LIGHT MACHINE SHOPL.M.S. is the largest section of the factory. All transmission components like sha�s and gears used tractor are manufactured here. L.M.S comprises of 70 machines, out of which 29 C.N.C. (Computer Numerical Control) machines. Except the bevel gear generator and gear shaver, which have been imported W.M.W. and Churchill (Germany) respectively and all other machines is from H.M.T. Ltd. 160 highly experienced operators and inspectors are working in this shop.

8.1 VARIOUS PROCESSES PERFORMED IN L.M.S. :

8.1.1 Grinding: Grinding practice is a large and diverse area of manufacturing and toolmaking. It can produce very �ne �nishes and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is usually better suited to the machining of very hard materials than is “regular” machining (that is, cutting larger chips with cutting tools such as tool bits or milling cutters), and until recent decades it was the only practical way to machine such materials as hardened steels. Compared to “regular” machining, it is usually better suited to taking very shallow cuts, such as reducing a sha�’s diameter by half a thousandth of an inch (thou) or 12.7 um.

Fig. 8.1 LMS Layout

Fig. 8.1.1 Aluminium Oxide abrasive, Bore gauge, Grinding machine

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Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny 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 �elds, the term cutting is o�en understood to refer to the macroscopic cutting operations, and grinding is o�en mentally categorized as a “separate” process. �is is why the terms are usually used in contradistinction in shop-�oor practice, even though, strictly speaking, grinding is a subset of cutting.

8.1.1.1 Various grades of grinding wheel abrasive are :• A (Aluminium Oxide)• C (Silicon Carbide)• Z (Zirconia)

8.1.1.2 Various types of grinding in L.M.S. :

A. Cylindrical Grinding: Cylindrical grinding (also called center-type grinding) is used in the removing the cylindrical surfaces and shoulders of the workpiece. �e workpiece is mounted and rotated by a workpiece holder, also known as a grinding dog or center driver. Both the tool and the workpiece are rotated by separate motors and at di�erent speeds. �e axes of rotation tool can be adjusted to produce a variety of shapes. �e �ve types of cylindrical grinding are: outside diameter (OD) grinding, inside diameter (ID) grinding, plunge grinding, creep feed grinding, and centerless grinding.

Jobs : drive sha�, bevel pinion, B.P.S. (le�), B.P.S. (right), bevel wheel.

B. Internal Grinding: Internal grinding is used to grind the internal diameter of the workpiece. Tapered holes can be ground with the use of internal grinders that can swivel on the horizontal.

Jobs : drive sha�, bevel pinion, input sha�.

8.1.2 Hobbing: Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine, which is a special type of milling machine. �e teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting

Fig. 8.1.2 B.P. Sha� (�nished and un�nished), B.P. sha� mounted in machine

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process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.Modern hobbing machines, also known as hobbers, are fully automated machines that come in many sizes, because they need to be able to produce anything from tiny instrument gears up to 10 � (3.0 m) diameter marine gears. Each gear hobbing machine typically consists of a chuck and tailstock, to hold the workpiece or a spindle, a spindle on which the hob is mounted, and a drive motor.

Jobs: Input sha�, gear Z-32, CM gear.

8.1.3 Gear Shaper: A gear shaper is a machine tool for cutting the teeth of internal or external gears. �e name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away from the part on the return stroke, just like the clapper box on a planer shaper. �e cutting tool is also gear shaped having the same pitch as the gear to be cut. However number of cutting teeth must be less than that of the gear to be cut for internal

Fig. 8.1.2 Helical gear and simple gear being hobbed

Fig. 8.1.3 �nished gears, gear shaper in action.

Fig. 8.1.2 bevel gear forming

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gears. For external gears the number of teeth on the cutter is limited only by the size of the shaping machine. Jobs: Internal gears.

8.1.4 Vertical Milling: In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. �e spindle can generally be extended (or the table can be raised/lowered, giving the same e�ect), allowing plunge cuts and drilling. �ere are two subcategories of vertical mills: the bed mill and the turret mill. Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down requires considerable e�ort and it also becomes di�cult to reach the quill feed handle (if equipped). �erefore, larger milling machines are usually of the bed type.

Jobs: Planet carrier.

8.1.5 Drilling : Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in solid materials. �e drill bit is a rotary cutting tool, o�en multipoint. �e bit is pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions per minute. �is forces the cutting edge against the workpiece, cutting o� chips from what will become the hole being drilled.

Fig. 8.1.4 Vertical Milling machine

Fig. 8.1.5 drilled component, non-drilled component, various drills and Vertical Milling machine

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8.1.6 Deburring : A burr is a raised edge or small pieces of material remaining attached to a workpiece a�er a modi�cation process. It is usually an unwanted piece of material and when removed with a deburring tool in a process called ‘deburring’. Burrs are most commonly created a�er machining operations, such as grinding, drilling, milling, engraving or turning. It may be present in the form of a �ne wire on the edge of a freshly sharpened tool or as a raised portion of a surface; this type of burr is commonly formed when a hammer strikes a surface. Deburring accounts for a signi�cant portion of manufacturing costs.

�ere are many deburring processes, but the most common are mass-�nishing, spindle �nishing, media blasting, sanding, grinding, wire brushing, abrasive �ow machining, electrochemical deburring, electropolishing, thermal energy method, machining, and manual deburring. Manual deburring is the most common deburring process because it is the most �exible process. It also only requires low cost tools and allows for instant inspection.

8.1.7 Broaching: Broaching is a machining process that uses a toothed tool, called a broach, to remove material. Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semi-�nishing, and the �nal one for �nishing. Broaching is an unusual machining process because it has the feed built into the tool. �e pro�le of the machined surface is always the inverse of the pro�le of the broach. �e rise per tooth (RPT), also known as the step or feed per tooth, determines the amount of material removed and the size of the chip. �e broach can be moved relative to the workpiece or vice-versa. Because all of the features are built into the broach no complex motion or skilled labor is required to use it.

Fig. 8.1.6 Gear before and a�er deburring.

Fig. 8.1.7 Broaching machine and internal teeth formed through broaching in an internal gear.

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8.1.8 Boring: In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by means of a single-point cutting tool (or of a boring head containing several such tools), for example as in boring a gun barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring can be viewed as the internal-diameter counterpart to turning, which cuts external diameters.

Fig. 8.1.8 Boring Machine

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9. Training Report

AIM : To eliminate unsafe condition at de-burring machine

De�ne the problem:To improve safety on M/C 665.02, during the operation of de-burring lots of chips of particle size are created which scatter everywhere. �is causes safety hazard to the operator and also it leads to bad housekeeping.

Analysis of the problem:

What?Bad housekeeping and safety problem at M/C 665.02.

Where?M/C 665.02

When?De-burring regular procedure.

Who?Because of production process by which de-burring is done.

How?Using QC tools and technique.

Classi�cation of causes1. Problem in process (process not correct)2. De-burring wheel not ok.3. Process done by operator not correct.4. No provision for avoiding dust.5. Table symmetry not ok.6. Operator not wearing PPE.7. Scattering of dust being caused due to some internal agent.

�e vital cause was analyzed by WHY-WHY analysis:

�e problem is that there is no proper way for chips to get away.

No provision for chips to get out of process in a regular way.

No cover or sink is there that collects the chips and removes them from the place properly.

It is dangerous for the operator in operating time.

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Developing solution:1. To use the chips collecting dust cover2. Goggles to be given to the operator.3. Gloves to be given to the operator.

Decided solution:A chips dust cover is used to store the chips to the back side in the direction of chips and goggles and gloves are provided.

MACHINE MAN

METHOD METERIAL

TABLE SYMMETRY NOT OKAY

PROBLEMS IN PROCESS

DEBURRING WHEEL NOT OKAY

NO PROVISIONS FOR DEVIATING DUST

SCATTERING OF DUST BURR CAUSED DUE TO SOME

EXTERNAL AGENTS

TO IMPROVE SAFETY&

HOUSEKEEPING

APPROACH OF OPERATOR NOT CORRECT

OPERATOR NOT WEARING PPE

Fig. 9.1 Fishbone diagram

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S/N MACHINE NAME MACHINE NO. LEAKAGE

1CNC Turning (twin

chucker)

196.01 Pneumatic leakage from left side auto-door

196.03 Leakage in axis motor (left) and spindle motor (both)

196.04 Leakage from hydraulic unit

2 Shaper 614.01 Hydraulic oil leakage from motor of hyd. unit

3 Internal gear shaper 615.01 Cutting oil leakage from T-joint

4 Hobbing

624.06Hydraulic oil mixes with cutting oil

624.07

624.14 Hydraulic oil leakage from unit (Joints)

624.05 Hydraulic oil leakage from tank

5 Gear tooth rounding 667.01 Hydraulic oil leakage from unit

6 Broaching 354.01Leakage from Hydraulic unit (approx. 10 Joints), DC Valve & Flow control

valve

7 Vertical Milling 497.01 Hydraulic oil leakage (Minor)

8 Bevel Generator 645.04Hydraulic oil leakage from; hydraulic unit (joints), bottom of machine and

feed gear box

9 Bevel Pinion Generator 645.03 Hydraulic oil leakage in feed gear box

10 Bevel Wheel Generator 645.02 Hydraulic oil leakage from; hyd. unit & bottom of machine

11 Cylindrical Grinding 523.03 Leakage in magnetic separator motor & hyd. unit

12 Bevel Wheel Grinding 536.03 Hydraulic oil leakage from hyd. unit (joints)

13 CNC Internal Grinding

554.01Air leakage from air pipe (tape has been applied); Hydraulic oil leakage from

workhead (from backside) due to improper sealing

554.03Pneumatic leakage (air inlet pipe’s valve handle); hydraulic oil leakage

(pressure regulator joint of hyd. unit)

554.02 Pneumatic leakage (minor); coolant leakage from coolant motor

554.05 Hydraulic oil leakage from hyd. tank

14CNC Cylindrical

Grinding

538.01 Lubrication oil leakage from lubrication oil motor

538.02Coolant leakage from coolant motor; pressure gauge oil leakage; hyd. oil

leakage from hyd. unit; minor oil leakage from lubrication unit

15 Cylindrical Grinding

535.01Hydraulic oil leakage from wheel head motor; Hydraulic oil leakage from under the table base; Hydraulic oil leakage fro machine front base (circuit

panel)

535.02Leakage in magnetic separator motor (lubrication oil); Hydraulic oil leakage from machine front; coolant leakage above coolant spray; Hydraulic oil

leakage in wheel head motor

535.03 Hydraulic oil leakage from hyd. tank; coolant leakage

16 CNC Turning 166.05 Hydraulic oil leakage

17 Milling 497.03 Hydraulic oil leakage from hyd. motor; coolant leakage from chip conveyor

18 Radial drilling 437.13 Hydraulic oil leakage from electrical unit

19 4-Way Boring 482.01Pneumatic leakage from supply pipe; Hydraulic oil leakage from hyd. unit

oil pump

20 Cylindrical Grinding

537.01

Hydraulic oil leakage from lever joint537.02

21 Gear tooth rounding 668.03 Cutting oil leakage

CHECK ING FOR LEAKAGES IN L .M.S MACHINES

Page 45: Swaraj Training Report

Page 22

10. Conclusion of trainingMy training was the most versatile experience. I had the pleasure to do the work with one of the most reputed factory in their �eld-“PANJAB TRACTORS LTD.” I received the blend of experience in Private as well as in Govt. sector. It was a good learning time during my training as we were fortunate to be placed in the department related to manufacturing. I feel training has give me exposure to undergo projects in the Manufacturing �eld as well help me a lot to understand the company work culture, working with teams and much more. In the end I will like to thank all persons who helped me throughout my training to enhance my experience. I also pay my regards to my Lecturers for their guidance during my training and my Academics helped me to do a lot during my training.