report on indo farm

8/13/2019 Report on Indo Farm

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CHAPTER 1

FOUNDARYSHOP

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MELT SHOP

This department is engaged in preparing the molten metal,

which has to be ultimately poured in green sand mold to

produce a casting. Before pouring into the mold, the metal to

be cast to be in the molten or liquid state. An IND!TI"N

#$NAN!% is used for melting the metal.

The selection of a furnace depends upon the followings factors.

Initial cost of furnace.

#uel costs.

&ind of metal or alloy to be melted.

'elting and pouring temperature of the metal to be cast.

(uantity of metal to be melted.

'ethod of pouring desired.

!ost of melting per unit weight of the metal.

#le)ibility of the unit.

!ost of the finished product desired.

*peed of melting the alloys.

Degree of cleanliness or pollution.

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Degree of control required.

There is one melt shop. There are two induction furnaces, and

these furnaces are of main frequency - cycles/sec0

#urnace no.1 !apacity1. - tons

#urnace no. + !apacity1. - tons

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INDUCTION FURNACE

Introduction:

An induction furnace is an electric furnace in which the heat is

applied by induction heating of a conducti3e medium usually a

metal0 in a crucible around which magnetic coils are wound

.The ad3antages of the induction furnace is a clean ,energy

efficient and well controllable melting process compared to

most other means of metal melting .'ost modern foundries use

this type of furnace and now also more iron foundries are

replacing cupolas by induction furnaces to melt the cast iron ,

as the former emit lots of dust and other pollutants.

Principle of Induction Furnace:

Induction is the production of electric charge, magnetism orelectromoti3e force in an ob4ect as an electric conductor, a

magnetically body, an electric circuit0 by the pro)imity without

contact of a similarly energi5ed body of the 3ariation of a

magnetic flu).

%ddy currents induced by a 3arying electromagnetic field

accomplish induction heating and melting .The current is

caused to flow through the material to be heated or melted or

through its container, i.e., crucible0 by electromagnetic

induction.

Induction heating

Induction melting

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Induction eatin!:

Induction heating is the process of heating a metal ob4ect by

electromagnetic induction, where eddy currents are generated

within the metal and resistance leads to 4oule heating of the

metal. An induction heater for any process0 consists of an

electromagnet, through which a high frequency A! current is

passed . 7eat may also be generated by magnetic hysteresis

losses.

Induction heating allows the precision heating of an applicable

item, for applications from surface hardening to melting,

"ften ,iron and its alloys respond best to induction heating ,

due to their , ferromagnetic nature. %ddy currents can,

howe3er, be generated in any metallic conductor, and

magnetic hysteresis can occur in any magnetic material.

Induction "eltin!:

Induction melting also uses electrical eddy currents induced in

the charge to heat and melt metal by its electrical resistance.

This is accomplished by electrically coupling the charge with

the alternating current coil.

Induction is widely used in the production of iron and steel

castings, for melting aluminium, 5inc, copper, and a great

3ariety of other nonferrous alloys.

Induction furnace:

An induction furnace uses induction to heat a metal to its

melting point. "nce molten, the high frequency magnetic field

can also be used to stir the hot metal, which is useful inensuring that alloying additions are fully mi)ed into the

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melt .'ost induction furnaces consist of a tube of water cooled

cooper, rings, surroundings a container of refractory material.

Induction furnaces are used in IND"#A$' %(I8'%NT 9I'IT%D,

as a cleaner method of melting metals than a re3erbatory

furnace or a cupola .*i5es ranges from hundreds of :ilograms

capacity, to ten tonnes capacity. Induction furnaces often emit

a high pitched whine or hum when they are running, depending

on their operating frequency. 'etals melted include iron and

steel, copper, aluminium, and precious metals.

Con#truction:

The two most common induction melting furnace designs are;

!oreless furnaces

!hannel furnaces

!oreless melting furnaces use a refractory en3elope to contain

the metal, and surround that by the coil. "peration on the samebasis as the transformer , the charge act as a single secondary

tern, there by producing heat by eddy current flow when power

is applied to the multi turn primary coil. Induction channel

furnaces were used initially as molten metal holders, but are

now used for some melting applications as well. An inductor,

comprised of a water cooled coil, is the energy source. Achannel is formed in the refractory through the coil, and this

channel forms a continuous loop with the metal in the main

part of the furnace. The hot metal in the channel circulates into

the main body of the metal in the funace. The hot metal in the

channel circulates into the main body of the metal in the

furnace, source of primary molten metal is required for the


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starup of a channel furnace .These furnaces do ha3e lower

surface turbulence within the main metal bath.

!oreless furnaces are preferable where gas pic:up and 3olatile

metal alloy loss is a problem. !hannel induction furnaces are

often selected for holding metal at temperature.

=hile all channel furnaces are line frequencies + 75 through

1+ 750 or high frequency o3er 1+ 750.9ine frequency

furnaces are slower to start from a cold charge resulting in

growing preference from medium and high frequency units.Impro3ements in frequency con3erters and lower costs ha3e

also aided acceptance.

CORE SHOP

This shop is engaged in preparing cores, which are ultimatelyused in the >mould assembly?

*tage of foundry process of producing hollow ca3ities incastings.

This shop consists of two areas

1. !ore sand control area

+. !ore ma:ing area

Core:

Core i# an o$#truction %ic %en po#itioned in te

"old &naturall' doe# not per"it te "olten poured

"etal to fill up te #pace occupied $' te core(

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1. !ores are required to create the recesses, undercuts and

interior ca3ities that are often a part of castings. !ores

made of core sand are generally employed.

Function of Core#:

1. #or hollow castings, cores pro3ide the means of forming

the main internal ca3ities.

+. !ores may form a part of green sand mold.

2. !ores may pro3ide e)ternal undercut features.

6. !ores may be employed to impro3e the mold surface.

-. !ores may be inserted to achie3e deep recesses in the

castings.


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Core Sand Preparation Sand Control:

This department is engaged in preparing sand mi)tures fordifferent types of cores that are being made in core shop.

This shop consists of

Base sand containers+

Bench hoppers C 6

!"$% BA&INE

'A&INE T7% !"$%

!"$% A**%'B9INE

!"$% #INI*7INE

!"$% D$FINE

!"$% *%TTINE


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*and mullers C 1- and C 2-

*and trolleys

Bench hoppers for small coresTypes of sand mi) in sand control;

*hell sand mi)

7ot bo) sand mi)

!old bo) sand mi)

"il sand mi)

No ba:e sand mi)

Fi! +,

CORE DR-IN*:

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The cores on which wash has been applied needs to be dried

before their supply to assembly area near the :w line. #or this

purpose two types of o3ens are generated used

Bo) "3en

Gertical "3en or tunnel "3en

Gertical o3ens are used to dry small si5ed cores while bo)

o3ens are used to dry large si5e cores.

!ores are placed on sliding drawers, which can

accommodate cores of different si5es , thic:ness and

length

Specification of .O/ O0EN:

Time for ba:ing C 16- minutes

#ront Door Temperature C 1@ to +1

$ae #ace Temperature C + to +6

9eft face Temperature + to +6

$ight #ace Temperature C + to +6

Temperature setting on controller C +2-

Mediu" of Heatin!:

"il #rom Tan:

Blower

Ignition

CORE ASSEM.L-:

!ore assembly means 4oining together by pasting, leading or

bolting two or more components parts of the core before thecore can be set in the mold ca3ity.

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!ore paste is applied o3er the core with the help of finger,

by brushes or dipping.

!ore paste is formed out of talc , de)trin , molasses, flour ,water etc . !orepieces after being pasted , are

assembled , pressed and left to dry.

9arge core parts are assembled by nuts and bolts. Nuts

and bolts are of course co3ered with mud after 4oining the

core parts .

PATTERN SHOP

This department is engaged in manufacturing patterns, core

bo)es, 4igs, fi)tures, mold bo)es and blow plates etc. The

pattern shop is equipped with 'odern Technology machines

such as !'' !oordinate 'easure 'achine0,

!N!/!A'!omputer Numeric !ontrol/ !omputer Aided

'achining0 etc.

PATTERN:

8attern is the model of casting around which molding material

is filled to produce the mold ca3ity. 8atterns are called

foundary men mould forming tools.

8attern 'a:ing and Inspection;

The steps in3ol3ed in the pattern ma:ing and its inspection are

described as follows;

Ma#ter Pattern Ma1in! :

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#irst of all, a wooden master pattern is made with the help of

machines a3ailable in pattern shop. The 3arious allowances are

:ept in the master pattern since it is to be used for casting the

actual pattern i.e. the pattern is to be used for molding

purposes.

The 3arious types of allowances are as follows;

*hrin:age allowances.

Draft Allowances.

#inish or 'achining Allowance.

*ha:e Allowance.

Distortion Allowance

Srin1a!e Allo%ance:

All the metals shrin: while cooling e)cept bismuth. This is

because of the interatomic Gibrations, which are amplified by

an increase in temperature. The rate of contraction is

dependent on the material. The shrin:age Allowance is always

to be added to the linear dimensions .%3en in the case of

internal dimensions , the material has a tendency to contracttowards he centre and thus is to be increased.

Macinin!:

The pattern, which is mar:ed, is ready for machining. The

pattern is machined by the help of 3arious with the help of

!A'/!N! machine in which the gi3en 4obs is performed in the

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computer with the help of software and the machine follows

the instructions deli3ered by computer and complete the 4ob.

Pattern In#pection:

The machined pattern is chec:ed for dimensional 3erification

i.e., whether the pattern has got the dimensions as per the

drawing supplied by design office. If the pattern is

dimensionally "&, then it is sent for sample production.

Sa"ple Production:

The sample production of castings from the pattern is made if

the castings are not dimensionally sound, then design is

modified again and all the steps mentioned abo3e are repeated

until dimensionally sound casting is obtained.

Draft Allo%ance:

At the time of withdrawing a pattern from the sand mlod, the

3ertical faces of the pattern are in continual contact with the

sand, which may damage the mold ca3ity. To reduce the

chances of this happening, the 3erticals faces of the pattern are

always tapered from the parting line. This pro3ision is called

Draft Allowances.

Fini# or Macinin! Allo%ance#:

The finish or accuracy achie3ed in sand casting are generally

poor and therefore when the casting is functionally required to

be of good surface finish or dimensionally accurate, it is

generally achie3ed by subsequent machining. 7ence e)tra

material is to be pro3ided which is to be subsequently remo3ed

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by machining or cleaning process. The type of machining

allowance pro3ided would depend upon the metal cast, the

type of moulding used, the class of accuracy required on the

surface and the comple)ity of surface details.

Sa1e Allo%ance#:

Before withdrawal from the sand mold, the pattern is raped all

around the 3ertical faces to enlarge the mold ca3ity slightly,

which facilitates its remo3al. *ince it enlarge the final casting

made, it is desirable that the original pattern dimensions shouldbe reduced to account for this increase.

Di#tortion Allo%ance:

A metal when it has 4ust solidified, is 3ery wea: and therefore is

li:ely to be distortion prone. This is particularly so far wea:er

sections such as long flat portions, G, sections or in!omplicated casting which may ha3e thin and long sections

which are connected to thic: sections. The foundry practice

should be to ma:e e)tra material pro3ision for reducing the

distortion.

Ca#tin! te Pattern:

The actual pattern, which is to be used for molding purposes, is

cast with the help of master pattern. The ca3ity is made by

pac:ing the green or some self setting sand mi) around the

master pattern and then remo3ing the wooden pattern. The

molten metal is poured in the bo) in which impression of

master pattern is made and after the metal poured has cooled

the cast actual pattern is ta:en out of the molding bo).

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MOLD SHOP

'old shop is the biggest machine in fettling as compared to

other shot blasting machines as it deals with totally blac:

castings e.g. %I!7%$ B9"!&, A*7"&A 9%F9AND B9"!& etc.

after passing thro the sha:er it is brought to this machine.

Mold Ma1in!

8repare molding sand is pac:ed rigidly around the pattern

and when the pattern is withdrawn , a ca3ity

corresponding to the shape of the pattern remains in the

sand and is :nown as mold ca3ity.

Thus a mold is sort of container which when poured with

molten metal produces a casting of the shape of the mold.

The process of ma:ing molds is referred to as 'old

ma:ing.

Caracteri#tic#:

A "old"u#t:

8ossess refractories to bear the high heat of the molten

metal.

8ossess strength to hold the weight of molten metal.

8roduce a minimum amount of mold gases.

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Be able to resist the erosise action of the molten metal

being poured.

$esist metal penetration into the mold walls.

Macine "oldin!:

=hereas in bench , floor and pit molding , the different

molding operation are carried out manually by hands of

the molder , 3arious molding operations li:e ramming ,

rolling the mold o3er, with drawimg the pattern etc. are

done by machines.

'achine performs these operations are much fast, more

efficient and in a much better way.

'olding machines produce identical and consistent

casting.

'olding machines are preferred for mass production of

casting whereas hand molding is used for limited

production.

'achine molding is not a fully automatic processK many

operations can though be performed by machines, yet

some others ha3e to be carried out by hands.

A few different types of molding machines are listed

below;

10 Jolt machine

+0 *quee5er machine

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20 Joltsqueer5er machine

60 *and slinger

*reen #and "oldin!:

It is most widely used molding process

The green sand used for molding consist of silica sand,

clay, water, and other additi3es.

"ne typical green sand mi)ture contains 1 to 1-L clay

binder, 6 to


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Time and cost associated with mold ba:ing or drying is

eliminated .

Ereen sand molds ha3ing smaller depths permit theescape of mold gases without any difficulty.

In green sand molding , flas:s are ready for reuse in

minimum amount of time .

Ereen sand molding pro3ides good dimensional accuracy

across the parting line.

Ereen sand mold in3ol3es less danger of hot tearing of

casting as compared to dry sand molds.

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FETTLIN* SHOP

Introduction to fettlin!

After sha:ing the casting out of mould, it is con3eyed to the

fettling dressing0 shop for cleaning and finishing. The fettling

process cleaning and finishing0 consist of the following

operations;

Decoring or core remo3al

!leaning of surface

$emo3al of gates, risers and fines etc.

$epairs of defecti3e castings if possible and heat

treatment.

Before starting the fettling process, the castings are e)amined

for ob3ious defects such as misrun, drop, cold laps and cold

shuts etc. Defecti3e castings are set aside are not cleaned.

,( Core re"o3al or core 1noc1out:

Due to the reason mentioned under Hsha:e out operation, thisoperation is also done mechanically. 7ammering and 3ibrating

will loosen and brea:up cores. *tationary or portable 3ibrators

are employed for this purpose.

2( Cleanin! of #urface#:

This operation in3ol3es the remo3al of all adhering sand and

o)ide scale and produces a uniformly smooth surface.

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'echanical methods are employed for this purpose, since

cleaning by hand with wire brush in tedious and costly.

These methods include;

Tumbling

*and blasting and shot blasting

Airless shot blasting

7ydro blasting

4( Re"o3al of !ate# and %ire#:

Eates, risers, and sprue can be remo3ed before or after

cleaning operation. In brittle materils, these are simply bro:en

off from the castings. In more ductile, materials, the following

methods are used to remo3e them;

8ower hac:saw

Band saws

Dis: type cutting benches

Abrasi3e cut off wheels

#lame cutting with an o)yacetylene cutting torch

Arc cutting for heat resistant and acid resistant steels

Fettlin! procedure:

+2

EAT%* AND $I*%$

8$% *7"T B9A*TINE

8"*T *7"T B9A*TINE


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SHOT .LASTIN*

These method are widely used to clean surfaces of light,

medium and hea3y castings. In these machines, dry and sand

shots white !.I shot, steel shot0 or grit of white !.I or steel grit

is made by crushing shot0 is blown by a stream of compressed

air against the surfaces of the castings. The impact of the

abrasi3e particles tra3elling at a high speed, on the surface

remo3es the adhering sand and o)ide scale. Gelocity of the

abrasi3e particles lea3ing the no55le of the machine is in the

range of 2- to @- m/s and the air pressure is is the range of .@

'pa.

*hot blasting is done for the following purposes;

To clean the casting surfaces

$emo3al of sand

*cale remo3al

+6

E$INDINE

=%9DINE

8AINTINE

D%*8AT!7


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$ust remo3al

There are three machines installed in the fettling shop for this

purpose;

+-

SHOT .LASTIN*

.MD , INDA.RATOR .MD 2


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CHAPTER -2

MACHINE SHOP

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'A!7IN% *7"8As the name shows all the light parts of tractors such as

differential housing, power ta:e off shafts, splined shafts,

gears, rear wheel dri3ing hubs, portal shafts, main transmission

shafts etc. are machined here. Different operations such as

turning, grinding, hobbing, broaching, milling, drilling, boring,reaming, threading etc. are performed here two type of

materials are uses in light machine shop .

1. $olled steel in the form of bars for the manufacture ofshafts0.

+. #orged steel in the form of circular pallets for themanufacture of gear0.

9ight machine shop is di3ided into following sections.

!TTINE *%!TI"N

T$NINE *%!TI"N

AT" AND 'I*!%99AN%"*

T""9 $""'

8$"D!TI"N 89ANINE AND T""9INE 88T0

.AR CUTIN* SECTION:+

The bar cutting section deals with cutting .facing and centering

of the bars and pallets to desired diameter and thic:ness with

the help of different machines the different machines in bar

cutting section are.

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1. B%ND *A=.

+. !I$!9%$ *A=

2. 8"=%$ 7A!&*A=

6. !"9'N D$I99-. 'I99INE 'A!7IN%

In these machines, bend saw is more accurate and efficient

machine and also the only one fully automatic saw. The circular

saws are capable of cutting the bars of diameter e3en more

then +2mm. after bar cutting facing and centering is done

with the help of 3ertical .column drilling and milling machines.These bar and pallets are then transported to the turning

section of the 9'* 9ight 'achine shop0.

TURNIN* SECTION:+

In this section the centered and faced material is sub4ected to

3arious turning operation to form 3arious gears and shafts. The

operation underta:en here initially produce a gear and shaft

blan:s which are then machined into their respecti3e forms

according to their function. The series of operations performed

in this section are as under;

1. E%A$ B9AN& #"$'ATI"N.

+. E%A$ !TTINE.

2. E%A$ *7AGINE.

TOOL ROOM:+

Tool room is the one of sensiti3e machining area in the 9'*. It

mainly deals with the production of JIE M#IT$%. It is well

equipped with highly prOcised machines for instrument

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calibration and setting them to their best le3el of accuracy. The

3arious machines of the Tool room are as under;

D"B9% !"9'N JIE B"$INE

'I&$"'AT E%$'AN T%!7N"9"EF0.

7FD$"8TI! *=I** T%!7N""EF0.

'IT*I*%I&I JA8AN%*% T%!7N"9"EF0.

S+56 STUDER CNC *RINDIN* MACHINE :+

The important aspect of all the machines in the tool room istheir temperature sensiti3ity. Their optimum temperature is

++P! and their accuracy is .+ micron for the operation they

performes.

PRODUCTION PLANNIN*N* AND TOOLIN* :+

This area of 9'* is well equipped with the machines that are

used to build the cutting edge of the tools. The cutting tools are

sub4ected to inspection to measure the inaccuracy in their

geometry.

The tools are then grinded on highly prOcised and properly

inde)ed grinding machines to obtain their cutting edges. This

machining operation requires s:ill as the o3erall quality of the

component manufactured depends on the cutting tool used.

The 88T section is well equipped with gauges, broaches, hobs,

thread rolls, reamers, taps and sundary tools, turning and

milling cutters, Eleason cutters.

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#ig 2

These abo3e are the raw material used for the ma:ing gears.

These all are casted and forged in forging section. #orging is

done so that material cost is to be maintained as well as

machining cost also.

MACHINES IN THIS SECTION

AT" #AF; It is a special purpose lathe designed by Jones and

9ampson of America.

!"8FINE 9AT7%; It is used for copy turning of long shafts. A

cutting tool mo3ing hydraulically generated the profile of same

shape as that of masterpiece. 'ain features of this lathe are;

(i) Automatic multi cycle copying

(ii) 'a)imum performance and minimum maintenance

THREAD ROLLIN* MACHINE:+

It is a machine ha3ing two master rollers on which threads are

present. Both rollers are mo3ing in cloc:wise direction. Job is

inserted between two rollers for cutting of threads. There is a

fi)ed time period for the roller for operator can fi) the thread

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cutting. In the bac: these threads are attached with the

"ldham?s couplings for lateral misalignment.

HO..IN*: +

It is done on single purpose hobbing m/c. *o far as design is

concerned there are two basic types i.e. 7+ wor: spindle and

Gertical wor: spindles. The Gertical type is more widely used.

'ultiple spindle m/c is used when production requirements are

high.

The 4ob spindle has two ad4ustments 1st the tool head is

mounted on a swi3el base so that the a)is of the hob spindle

may be set at an angle to a)is of the wor: spindle. The angle

depend upon the heli) angle of the :ind of gear being cut and

second, the hob spindle may be ad4usted a)ially as a means of

distributing wear on the tools.

Fi! +5

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These are some picture of component which are being madethere.

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MACHINE SHOPIt is a part of tractor di3ision in which two types of hea3y

casting Eear bo) and 'T housing0 are machined and some

other components are also manufactured. In this shop the

machines are arranged according to the sequence of operation

and 4ob mo3es from one machine to another in series. This type

of layout results in lerrer amount 'aterial 7andling. Themachines used basically are special purpose machines *8'0

which are manufactured and for a particular operation. The

3arious types of machines present in this shop are;

*emiAutomatic 'achines;

$adial Drilling 'achine.

7ori5ontal 'illing 'achine.

Gertical 'illing 'achine.

Boring 'achine.

Inclined Boring 'achine.

Dual 'illing 'achine.

Turret 9athe 'achine.

Two =ay 'ultiple Drilling 'achine.

Thread 'illing 'achine.

!ylindrical Erinding 'achines.

!omputer Numerical !ontrol !N!0;

7ori5ontal 'illing !entre -.

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7ori5ontal 'illing !entre


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*EAR.O/:+

Eearbo) is that part of tractor which is mounted in the tractorbetween the %ngine and 'ain Transmission 7ousing. Its main

moti3e is to transmit the power from the engine to rear wheels

with reducing and increasing amount of *peed and Torque of

the Tractor as per its operating load condition.

The type of Eearbo) used in the tractor is *9IDINE '%*7 E%A$

B". In the Eearbo) the 8ower comes from engine to the clutch

shaft and hence to the clutch gear which is always in mesh with

a gear on the lay shaft. All the gears on the lay shaft are fi)ed

to it and as such all the time rotating when the engine is

running and clutch is engaged. The gears present on the

splined shaft are free to slide on it.

#ollowing are the main components of gearbo);

a0 Input shaft assembly. b0 "utput shaft assembly.

c0 9ay shaft assembly. d0 Intermediate shaft

assembly.

e0 !lutch Actuator guide ass. f0 Eears.

g0 Eear bo) housing. h0 *hifter rods.

I0 *hifter for: 40 Bearings.

:0 #asteners, gas:ets and spacers.

These gears are arranged in such a manner that when they

mesh with 3arious other gears they gi3e different amount of

*peed and Torque. These assemblies of gears and shafts are

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mounted on the gearbo) casting with the bearing, so that all

the thrust of the gearbo) comes on the casting and the casting

of the gearbo) remains strong and can ta:e all of the load and

thrust of the fear without any distortion.

After the manufacturing of the casting of gearbo) comes in

7'* shop for the machining operations, 7ere many operations

li:e Drilling, Eroo3ing, 'illing, #acing and many other

operations are done on the gearbo).

#ig -

The 3arious operations carried out on the E%A$B" 7ousing as

it flows through the production line are;

a0 'ar:ing. i0 Tapping.

b0 #ace 'illing. 40 #itting.

c0 Drilling. :0 =ashing.

d0 #ace 'illing. l0 Erinding

e0 Boring. m0 Inspection

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f0 Drilling.

g0 Drilling.

h0 #inish Boring.

MAIN TRANSMISSION HOUSIN*:+

The main transmission housing accommodates the differential

which transmitt the power coming from the gearbo) to the half

a)les and further on the rear wheels. =hen the tractor is

tac:ing a turn the outer wheel will ha3e to tra3el greaterdistance as compared to the inner wheel at the same time.

Therefore if the Tractor has a solid rear a)le only and no other

de3ice will be tendency for the wheel to s:id. 7ence if the

wheel s:idding is to be a3oided some mechanisms must be

incorporated in the rear a)le, which should reduce the speed of

the inner wheel, and increase the speed of the outer wheel

when ta:ing a turn, the de3ice which ser3es the abo3e function

is termed as differential.

The 3arious operations carried out on the 'T 7ousing as it

flows through the production line;

a7Mar1in!:+ #irst of all the ma:ing of reference line withrespecti3e to the bores on the'T 7ousing !asing is done

before the machining operation. It ta:es place on the surface

table. The 'T 7ousing is mar:ed for the identification M

3isuali5ing of the machining depth and the right position of

the bores and drills on e3ery si) sides of the 'T 7ousing.

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$7Face Millin!:+'illing of the top and bottom face is done on

the Duple) 'illing 'achine. The diameter of the face cutter

is almost equal to the width of the area of wor:piece to be

machined.

c7 Drillin!:+The Drilling of the + location holes on the bottom

face of the 'T 7ousing is done on the radial drilling machine.

The location holes are drilled in order to clamp the wor:piece

on the fi)ture and also acts as reference holes for the other

dimensions.

d7Face Millin!:+The 'illing of the left and right face of the 'T

7ousing is done on the Duple) 'illing machine. "n this

machines where are two spindles and the machining of the

both faces is done correspondingly.

e7Face Millin!:+The 'T 7ousing is clamped on the bed with

help of the location holes and the face milling of the front

and rear face is done.

f7 .orin! : The boring operation is carried out on the left and

right side of the 'T 7ousing.

!7Drillin! :+The drilling operation is carried on the front and

rear sides of the 'T7ousing. The operation is carried out onTwo =ay 'ultiple Drilling machine. %ach spindles of 3arious

drills rotates with 3arying speeds.

7Tappin! :+Tapping of the holes is done on the $adial drilling

machine with the use of tapping tool.

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i7 8a#in! :+The cleaning of the wor:piece is done by using

hot waterheated at


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The entire main machine structural?s elements li:e Bed , *addle

!olumn , 7ead, and pallet changer are built out of closed grain

cast iron e)cept the pallet inde) base and pallet changer slide

which are made of welded steel structures.

8a' $earin! arran!e"ent:+

The entire three liner a)es are ha3ing linear recirculation

motion bearing system which has a 3ery low coefficient of

friction. Their use eliminates stic:slip motion and thermal

generation a high speed positioning.The saddle mo3ement o3er the bed pro3ides a)is motion,

column mo3ement o3er saddle pro3ides C a)is motion , and

head mo3ement o3er column pro3ides Fa)is motion .

FEED dri3e#:+

*lides are dri3en by independent A!ser3o motors enabling

high acceleration deceleration and accurate contouring with

infinitely 3ariable feed rates .to cut down idle time during

positioning a rapid tra3erse rate of +m/min has been pro3ided.

'otors are directly coupled to ball screws through torsion ally

stiff coupling in all three a)es. Ball screws are mounted on stiff

e)tra precision angular contact preloaded bearings. The

position feed bac: is pro3ided through encoders in built into the

motor resolution in stiff closed loop ser3o system.

SPINDLE ead:+

It carries spindle assembly, timing belt and pulley

arrangement , power draw bolts and spindle orientation

mechanism spindle motor hori5ontally mounted at the rear of

the head pro3ides power to spindle a resol3er is fitted at the

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rare of the motor to pro3ide analogue speed feedbac: signal to

the control system . the dri3e is equipped with thermal o3er

load circuit to perfect motor and dri3e.

AUTO TOOL CHAN*ER:+

'achine is equipped with hydraulically operated double ended

tool changing arm. Tool selection is random and bidirectional

through coded poc:et system. Tool maga5ine is standalone unit

mounted on the left side of the bed. *tandard maga5ine carries

2+ tool poc:ets.

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CHAPTER -3

ENGINE SHOPENGINE SHOP

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EN*INE SHOPEN*INE SHOP

In engine shop there are manufacturing of the entire

component which is being used in engine assembly. =e ha3e

seen all the machining process which are used to made a

particular component for e)ample connecting rod it ta:es 1-

different machines to be fully completed.

Fi!ure =

This is the first state after casting in this picture 1 only facing is

being done. #acing is done thrice time to fully complete the

connecting rod.

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Fi!ure >

Abo3e figure is of hori5ontal milling machine which is used to

cut the connecting rod to two basic hal3es one is the main

connecting rod and another is the clamp which clamp the

connecting rod into cran: shaft in cran: case.

Fi!ure ?

This is the intermediate step for connecting rod after cutting to

two hal3es. Below is the second part that is clamp.

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Fi!ure @

In this shop we ha3e also studied about rear and front a)le,

roc:er arm cran: case. In short in engine shop we ha3e studied

the entire components which are used to complete the engine.

EN*INE SHOP

In new engine shop two main type of part of tractor engine aremade one is cran: case of two cylinders, three cylinders, four

cylinder and second one is cylinder head.

#ig 1

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This is the bottom face of cran: case which is faced by using

special purpose milling machine. The process which are being

used for machining is

1. 'ar:ing below is the fi)ture of mar:ing of three cylinder

engine cran: case

Fi! +,,

10 The second process is facing of one side by putting in fi)ture

made on *8'+0 Then ta:ing reference we drill two guide whole, with the help

of this guide whole all the faces are finished by *8'

machines.

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#ig 1+

Then all the required whole are drill by drilling machines.

+ndis the cylinder head

Below is the first stage of cylinder head after casting

Fi! +,4

10 #irstly we ha3e faced the one face after mar:ing and put into

the fi)ture. As *hown in the figure.

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#ig 16

+0 Now with reference of this first face we operate all the ne)t

step that are facing of all the si) faces.

20 Then drilling is done.

60 Al last inspection is done on marble which has high accuracy

of flatness to gi3e correct testing.

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CHAPTER -4

ENGINEASSEMBLY &

TESTING

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EN*INE ASSEM.L-

PROCEDURE OF EN*INE ASSEM.L-

10 =ash the bloc: gently there should be no dust or dustparticles.

+0 !hec: all the holes and drillings and confirm that the bloc:

is ha3ing accurate, measurements.

20 #it the bloc: tightly and chec: all the fittings.

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#ig 1-

CRAN) SHAFT ASSEM.L-:+

10 'ain bearing fitment;#or the proper lubrication of cran:.

+0 !ran: shaft fitment;#or the proper fitment of seal.

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20 $eal oil seal fitment;#or the proper fitment of seal.

60 "il 8ump fitment; #or the proper fitment only.

-0 'ain oil seal run out; #or the ensure the centrali5ation ofmain oil seal.

#ig 1( Oter Lea1a!e#:+

a. 8T" oil seal.

b. Differential drain plug.

c. "il filter.

d. #lywheel housing 4oint.

?( S"o1e cec1in! ;3i#uall'7(

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CHAPTER-6

QUALITYASSURANCE

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UALIT- ASSURANCE

(uality assurance acti3ity in 7'T is an 'I* function to audit

and report the quality status of both , products well as quality

assurance systems within the plant considers the 3endors as an

e)tension as its own manufacturing operations. 7ence the

quality assurance audits are not limited to 4ust recie3ed

components at 7'T receipt inspection stage but e)tends to

audit of conformance to prescribed quality assurance systems

at 3endor end also.

O.ECTI0ES:+

,. To reduce re4ection and achie3e better quality standards.

2( To achie3e consistency in quality.

(uality which has no compromise, is essential for e3ery

industry to stay affirm in today?s competiti3e world. 'y pro4ect

is a long term pro4ect for e3ery industry. %ach industry feels to

upgrade its position and 3endors are integrated parts of it.

(uality impro3ement at 3endor?s end means o3erall

impro3ement in company?s gradation. =ith high quality from

3endor, ma4or goals of impro3ement can be achie3ed.

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CONCLUSION

=or:ing with IND" #A$' %(I8'%NT 9TD. as a summertraining was a 3ery nice e)perience. I also practiced what Ilearnt in the uni3ersity and applied it on field. =or:ing with thisautomobile department enhanced my ma4or understanding. Inaddition, I gained a good e)perience in term of self confidence,real life wor:ing situation, interactions among people in thesame field and wor:ing with others with different professional

bac:ground. I had an interest in understanding basicengineering wor: and practicing what has been learnt in theclass. Also, the training was an opportunity for me to increasemy human relation both socially and professionally.

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TECHNICAL SPECIFICATIONS OF INDOFARMTRACTORS

46=< DI:+78 $ANE%


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7igh Torque Bac:up

8ower *teering and "il Immersed Bra:es

*traight $ear A)le for %asy 'aintenance

INDO FARM 5,>< DI

D$IG% +=D AND 6=D%NEIN% 6*T$"&% @-78!9T!7 D"B9% !9T!78A$&INE B$A&% IND%8%ND%NT B$A&%

BATT%$TF 1+G"9T=7%%9 T$A!& 16+< DI

1+/1+ *peed !arraro Transmission.

*ynchromesh Eear Bo)

*ide *hifter Eear

Independent Dual *peed 8T" -6/1 rpm

9ift !apacity +


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REFERENCES

888(INDOFARM(IN

COMPAN- PAMPHLETS

Trul' #upported $' H(R depart"ent;indo far"7

report on indo farm

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