ics report final

8/11/2019 Ics Report Final

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G.H RAISONI COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL

ENGINEERING

ICS REPORT

DEO ENGINEERING COMPANY

GUIDED BY: Prof R. S. SHELKE


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INDEX

Sr.no TITLE PAGE NO.

1. INTRODUCTION 3

2. PROBLEM IDENTIFICATION 4

3. MACHINES USED IN THE INDUSTRY 6

4. PROCESS USED IN THE INDUSTRY 10

5. SOLUTIONS SUGGESTED TO OVERCOME

THE PROBLEM

11

6. ADVANTAGES OF THE SOLUTION 13

7. CONCLUSION 13

8. GROUP PHOTO OF STUDENTS WITH THE

INDUSTRY

14

9. CERTIFICATE 16


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INTRODUCTION:-

NAME OF INDUSTRY:-DEO ENGINEERING COMPANY

PROPRIETER OF THE INDUSTRY: - Mr. DIPAK BHENDE

ESTABLISHMENT YEAR:-2010

TYPE OF INDUSTRY:-MANUFACTURING AND MAINTENANCE PLANT

LOCATION: -ELECTRIC ZONE MIDC, NAGPUR

PRODUCTS PROCESSED: ENGINE CYLINDER, PISTON, CRANKSHAFT,STUDS, MACHINE BOLTS, MAHINDRA TRACTOR ENGINE PARTS

NUMBER OF PERSONS WORKING:-12

SHIFT TIMING:-12 HOURS

CUSTOMER: NECO CASTING, MAHINDRA AND MAHINDRA, VIJAY

AUTO WORKS

TURNOVER:-50 LAKHS PER YEAR.


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PROBLEMS IN THE INDUSTRY:-

IMPROPER DECARBONIZING:

While decarbonizing a surface they scrape off the top layer of the workpiece

with a grinding machine which causes removal of material and hence reduction

in original specified company dimensions which crosses the limit of tolerance.

They use sharp chiseled device like screw driver for port cleaning and

sometimes steel wire brush is also used which causes deep scratches on the

surface and which creates even more possible reasons for carbon deposition in

port surface and reduction in performance of engine.

IMPROPER BLOCK REPAIRING:

1. Improper boring

The boring done on the block is improper because the alignment of boring head

and machine table is not checked by proper device they only check it with their

eyes and depend on their visual perception. Because of this the internal walls of

the cylinder do not remain parallel and the new piston gets improper pressure on

one side which causes material loss of piston and piston rings from one side.

2. Improper honing:

After boring the block honing operation is done which is also not done with

proper machine. The block is hold against a object with the foot of operator and

a heavy duty drilling machine is used with honing head to operate on the block


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3. IMPROPER CHECKING OF THE JOB:

The checking tools the use for dimension measurement are not calibrated. They

do not send their tools for periodic calibration .the tools like bore dial gauge and

venire calipers need calibration periodically. Because of this their machined

products are not of company specified dimensions.

Surface roughness of bored block is not checked. While the block is bored and

honing operation is done very fine lines are created as a result of operation done

on the block. If these lines are deeper than the company specification then the

block diameter will again increase as the vehicle is set in operation. And the

problem of reduced performance will rise again.

4. USE OF NON STANDARD MACHINES:-

They use local machine as a result of this job is

improperly machined. The following problems occurred due to the use of local

machine. Concentricity of bore is not maintained. Surface of the inner wall of

the bore is rougher than the required specification.

5. NO SAFETY MEASURES MAINTAINED:

Workers dont wear gloves.

Workers dont wear safety industrial boots.


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MACHINES /EQUIPMENTS USED IN THE INDUSTRY

BORING MACHINE:-

Fig 1

This machine is to perform boring operation. Diameter of

hole is increased by using this machine. Single point cutting tool is used for this

operation. Greater accuracy is achieved by boring operation as compared to

lathe machine and drilling machine. The machine is manufactured by ILLAHI

MECHANICAL WORKS.


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DRILLING AND GRINDING MACHINE:-

This machine is used for both purpose that is drilling

and grinding. this is done by replacing the head of the machine according to

need. Speed of the motor is adjusted by proper gear mechanism. This machine

is manufactured by ILLAHI MECHANICAL WORKS.

Fig2


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HYDRAULIC PRESS MACHINE:-

Capacity of this hydraulic press is 40 tons. This

machine is manufactured by KALIA MACHINE SALES. The hydraulic press is

used for many purpose but mostly it is used to fit the piston in the cylinder, as

they are very closely fitted and cannot be assembled by hand.

Fig 3


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GRINDING MACHINE:

Grinding machine is used to even the rough surface of a metal workpiece . This

gives a smooth and mirror finish to the surface of the workpiece.It is also used

to remove unnecessary corners or extruding parts from the workpiece. This

machine is manufactured by KALIA MACHINE SALES.

fig 4


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PROCESSESS USED IN THE INDUSTRY:

This industry is a manufacturing as well as maintenance industry. But we have

taken the case of maintenance. The company gets orders from the customer and

solves their problem in following way:

The customer provides the company with damaged engine blocks and parts.

They analyze the reason behind the degraded performance of the engine and

give corrective measures like decarbonizing, proper cylinder piston

arrangement, crank shaft repair, etc.

CUSTOMER COMPANYPROBLEMANALYSIS

SOLUTIONREPAIR

REPLACECUSTOMER


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SOLUTION SUGGESTED TO OVERCOME THE

PROBLEM:-

PROPER DECARBORIZING:-

The carbon deposited on the block should be removed with the help of carbon

removing agents like KEROSINE or DIESEL. Mostly kerosene is used for this

purpose.

The affected part of the work piece should be soaked in kerosene for some

time. Then the work piece is taken out from the kerosene and a little heat is to

be applied for the carbon to be removed. Heat is applied by gas flame.

The port cleaning is the most important part of the decarburizing process. It

should not be cleaned with the help of sharp or chisel device or steel wire brush.

Use of these devices causes deep scratches with again accounts for even more

carbon deposition. Instead brass wire brush should be used. Brass wire brush is

softer as compared to metal of the block that is aluminum.

HONING:-

The stone of honing head should be dressed properly and

periodically. Honing head and machine table alignment should be checked with

proper devices not with visual perception.


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TOOL CALIBRATION:

The checking tools should be calibrated periodically otherwise while checking

the job it will show wrong values which would affect the dimensions and

ultimately affect the performance.

SAFETY MEASURES:

The workers should wear proper safety equipments like protective gloves and

industrial boots.


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ADVANTAGE OF SOLUTION:

The advantages of solution will be that the workers in the company will be safe

and more productive by maintaining safety measures. Standard machines andproper and timely calibration of measurement tools will result in proper repair

according to customer standards and requirements. Use of standard machines

will increase the production rate and reduce inaccuracy and rejection.

CONCLUSION:

Management is the key issues in the success of the industry and is very tough

issue as well. Minute detail in design can improve production and accuracy

many times. This in turn increases the quality of production and standard of

company.


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GROUP PHOTO OF STUDENTS WITH THE INDUSTRY:


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NAME OF STUDENTS AND SIGNATURE:

DHURJOTI CHAUDHARI, MECH (A-40)

GUNJAN NAKADE, MECH (A-49)

PAWAN DUBEY, MECH (A-50)

HEMANSHU G. GODBOLE, MECH (A-51)

PRADEEP ROY, MECH (A-52)


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CERTIFICATE

This is to certify that the students of G.H.RAISONI

COLLEGE OF ENGINEERINGhave suggestedsatisfactory solutions to the identified problems for

DEO ENGINEERING WORKS under the guidance

ofProf. R. S. SHELKE

(For DEO ENGINEERING

WORKS)

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