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PROJECT REPORT ON “STUDY AND UPDATION OF PROCESS OF CLYNDER” (BLOCK – E 3-312) UNDERTAKEN AT SUBMITTED TO :- SUBMITTED BY :- (DEPARTMENT OF MECHANICAL ENGG) CHETAN GOSAIN ROLL NO: 10512 MECHANICAL ENGG. 4 TH YEAR/ 7 TH SEMESTER

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Page 1: Escorts Training Report Cg

PROJECT REPORT ON

“STUDY AND UPDATION OF PROCESS OF CLYNDER” (BLOCK – E 3-312)

UNDERTAKEN AT

SUBMITTED TO:- SUBMITTED BY:-

(DEPARTMENT OF MECHANICAL ENGG) CHETAN GOSAIN

ROLL NO: 10512

MECHANICAL ENGG.

4TH YEAR/ 7TH SEMESTER

Page 2: Escorts Training Report Cg

ACKNOWLEDGEMENT

I am very grateful to “ESCORTS

AGRI MACHINERY (COMPONENTS

PLANT) AT PLANT NO 1 ”,

Management which gives me the

opportunity to work in their

organization. Through this training I

was able to get a feel of working in

an industry and could put to

practice the knowledge I had gained

so far in my college. I am greatly

indebted to my Project supervisor

Page 3: Escorts Training Report Cg

and the senior engineer Mr. SUNIL

SANDHU , who in spite of his busy

schedule guided me in my project

and was always also available for

discussion. He took active interest

in my training period and inspired

me to use this great opportunity to

learn about the various aspects of

seat slider, recliner and not just

limit myself to assigned the project.

Chetan gosain

Page 4: Escorts Training Report Cg

COMPANY PROFILE

OVERVIEW

ESCORTS LIMITED,THE FLAGSHIP COMPANY OF THE ESCORTS GROUP IS A LEADING MANUFACTURER AND SUPPLIER OF AGRI MACHINERY PRODUCTS, CONSTRUCTION & MATERIAL HANDLING EQUIPMENT, AUTO SUSPENSION AND ANCILLARY PRODUCTS AND RAILWAY EQUIPMENT.

(ESCORTS AGRI MACHINERY COMPONENTS PLANT AT FARIDABAD)

A pioneer of farm mechanisation in India, Escorts Agri Machinery (EAM) was launched in 1960. The

company manufactures tractor under the brand names of Escort, Farmtrac and Powertrac. EAM

consists of four manufacturing plants that cover an area of 134,000 sq.m. The company also has a

plant in Poland, which is a 100% subsidiary and functions in the name of Farmtrac Europe.

Page 5: Escorts Training Report Cg

Type

Industry

Founded

Founder(s)

Headquarters

Area served

Key people

Products

Employees

Website

Escorts Group

Public Limited

Engineering Conglomerate

1960

Hari Nanda and Yuri Nanda

Faridabad, India

Worldwide

Rajan Nanda (Chairman and Managing Director) and Nikhil Nanda

(Joint Managing Director)

Tractors, crop solutions, cranes, loaders, shock

absorbers, struts, steering components, brakes for

railways, couplers

6,000 (2011)

www.escortsgroup.com

and Nikhil Nanda

loaders, shock

absorbers, struts, steering components, brakes for

Page 6: Escorts Training Report Cg

Historical Background

Escorts came into being with a vision and a mission. A vision that led two brothers

YUDI NANDA and HARI NANDA to branch out from their family’s prospering transport

business and institute ventures that were to become the foundation of ESCORTS Ltd. Escorts

agents limited was born at Lahore on 17th Oct, 1944 with YUDI NANDA as managing director

and HARI NANDA as the chairman. After that owning to the opportunities lying in the Indian

villages Escorts (Agricultural Machines) Ltd., was launched in 1948 with YUDI NANDA as the

director. Tragically, he died in an accident in 1952. Then Escorts Agents Ltd . And Escorts

(Agricultural Machines) Ltd. Was merged in 1953 to create a single entity Escorts Agents Pvt.

Ltd. The company’s incorporation in its present name, Escorts Ltd. was effected on 18th January

1960.

Having initially started with a franchise for vesting house domestic appliances, Escorts has come

a long way in manufacturing and marketing a large range of products. It has pioneered farm

mechanization in India through import and distribution of agricultural tractors.

Page 7: Escorts Training Report Cg

The manufacturing operations commenced in 1954, and since then the following range of

products have been introduced in the country:-

1954: Piston rings and Cylinder liner

1960: Pistons

1961: Assembly of tractors

1962: Motorcycles and railway couplers

1963: Automotive shock absorbers

1965: Agricultural tractors under Escorts brand name

1969: Agricultural tractors under Ford brand name

1971: Industrial and construction equipment

1979: Excavator loaders

1981: 100cc motorcycles

1985: Electronic PABXs

1991: Harvester combines

1992: VSAT Satellite Communication System

1993: Mobile communications

1995: Fork lift trucks

1996: Disengagement of joint venture collaboration with New Holland and launch of

FARMTRAC Tractor.

The single word completely described the character philosophy and success of the company,

which grew from a small beginning to one of the ever-changing dimensions. For five decades

Escorts has been in the core sectors like Agriculture, Transportation, Construction & Resources

for Engineering change through optimum product performance. From its inception Escorts has

firmly believed that success inspiring on being close to the customer thus every corporate

endeavor addresses it to end used, adjusting to ever changing markets.At every step of the way,

Escorts had inducted the latest technology by forming alliances with the world’s most advanced

Engineering and Electronic companies, constantly adopting their technology according to India’s

need and situation. To make sure the finished product delivers on its promise the company had

created an extra-ordinary distribution and service network that stays with the customer.

Escorts came into its own with a far reaching vision for the future to stay over close to the

customers with products made in India to international standards. The source of Escorts

consistent growth is commitment and contribution to the core needs of the country. Escorts have

firmly believed that success depends on being close to the customers. As early as in 1944 while

Page 8: Escorts Training Report Cg

others were concentrating on selling their goods .Escorts sought to “Escorts” its merchandise

right up to the customer’s doorstep. This meant staying close to the customer, understanding their

needs, giving them a product that met these needs ensuring that it worked smoothly thereafter.

Today with Mr. Rajan Nanda as a Chairman and Mr. Anil Nanda as a Vice-

Chairman the ideals have not changed. Thus, every corporate endeavor addresses to the end

users and the ever-changing market, substantial man-hours are being devoted to planning a new

range with the objective of consistently offering greater value to the customer.

“In every area we touch our task has always remained one of engineering change”

Rajan Nanda. In every step, Escorts has induced the latest technology to make products that are

not merely “better” but those meet international standard. For Escorts, these are two benchmarks

of industrial achievements, the distinct, undisputed edge of technology and the

internationalization of business.

In five decades Escorts has grown to become one of the top industrial conglomerates in the

country

FIVE DECADES OF ENGINEERING CHANGE

THE DECADE OF CREATION: 1944-1954

The launch of Escorts Agents Pvt .In Lahore and setting it all up again in Delhi after the

country’s partition .The beginning of an industry legend, with a tractor franchise, followed by

India’s first institute of farm mechanization and the company’s first industrial venture, Goetze

(India) Ltd., at Patiala, in equity collaboration with Goetze of Germany.

THE DECADE OF AUTOMATION: 1955-1964

Escorts goes public. A full-fledged manufacturing orientation takes roots with the

commencement of Escorts’ own brand of tractors and next major field of operation: motorcycles.

The company joins hands with Mahle to produce India’s most advanced pistons.

THE DECADE OF CONSOLIDATION: 1965-1974

The foundation of the Ford-Escorts alliance for India’s finest tractors, soon to make the

group the largest selling tractor manufacturing .Escorts Employees Ancillaries Ltd., a unique

venture in industrial democracy, comes into being.

Page 9: Escorts Training Report Cg

Escorts receives FICCI Award for outstanding contribution to Indian agriculture .The

company crossed national boundaries with its first export of 400 tractors to Afghanistan, won in a

global tender. A triumph of Escorts quality and competitiveness, this was perhaps the world’s

largest ever commercial airlift of its kind.

THE DECADE OF DIVERSIFICATION: 1975-1984

One with Knorr Bremse follows an epoch-making alliance with JCB for India’s first

Excavator-loaders for railway breaks. With the Yamaha collaboration, Escorts become the

country’s largest motorcycle manufacturer. Acknowledged leadership in automotive ancillaries-

Mahle pistons and Goetze rings .

THE DECADE OF GLOBALISATION: 1985-1995

Escorts enters into joint venture with buy back arrangement with Class (Harvester

Combines) and Herion (Hydraulic valves) providing an entry to world markets. A tie-up with

Faun, powers the company to supremacy in hydraulic mobile cranes. Escorts fights an epic battle

against a corporate raid, the ultimate victory providing the unshakable confidence of the

company’s small shareholders countrywide. Escorts Heart Institute commissioned, hailed as

among Asia’s most advanced. Escorts turnover crosses Rs. 15 billion. In the sunrise telecom

sector, alliances with JS telecom, a Bosch company, and Hughes Network systems, world leaders

in VSAT networks.

THE DECADE AHEAD: 1996

The Mission is Globalization and the emphasis will be on core sector investments. Escorts

is going in for a global network and for mega projects in the 21st century.

Page 10: Escorts Training Report Cg

ESCORTS: RESTRUCTURING

Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its

inherent strengths, a strong presence in the Core Sector providing complementary product lines

and a vast marketing network; combining them with India’s intrinsic cost advantages to become a

global source point for high value engineering products.

Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its

inherent strengths, a strong presence in the Core Sector providing complementary product lines

and a vast marketing network; combining them with India’s intrinsic cost advantages to become a

global source point for high value engineering products.

In order to meet the challenge of the future and to leave an indelible mark on industrial scenario,

Escorts has restructured the group along 4 business lines, each headed by an independent CEO.

The business groups are as follows:-

1) Agri Machinery Group

2) Construction Equipments

3) Automotive Ancillaries

4) Financial Services

Page 11: Escorts Training Report Cg

ESCORTS – THE GROUP INFRASTRUCTURE

The flagship of the Escorts group is Escorts Ltd. in the words of Mr. Rajan Nanda. Chairman

Escorts Limited., “in the last 50 years Escorts has been more than merely one of India’s largest

Engineering Companies. It has been a prime mover on the industrial front; at every stage

introducing products and technologies that helped take the country forward in key areas. Today as

the nation engages in its most momentous economic transformation ever, we are once again

adapting ourselves towards being catalysts for qualitative growth by Engineering Change with a

global perspective.”

The group infrastructure comprises:-

23 main associates/subsidiary companies

1) 12 manufacturing locations

2) A full-fledged R&D facility

3) Nearly 10,000 employees

4) 24 regional marketing offices

5) Nearly 500 ancillaries forming the vendor base

6) 4 financial services companies

7) Asia’s best training institute of Farm Mechanization with 100 acre demonstration farm.

EDDAL Escorts Dealer Development Association providing management and financial support

to dealers .

Page 12: Escorts Training Report Cg

THE ESCORTS GROUP

THE FLAGSHIP COMPANY

o Escorts Limited

OPERATING DIVISIONS

o Agri machinery division

o Engineering division

o International business division

SUBSIDARY COMPANIES

o Escorts construction equipment Ltd. (cranes, exvators, truck loaders)

o Esconet services

o Escorts Automotives(Investment)

o Escosoft technologies

o Escortal tele communication ltd.

o Cellnext solutions

o Automatrix India

o Escorts heart institute & research center

o Escorts hospital & research center

Medical care (erstwhile division of Escorts lived off 100% subsidy)

ASSOCIATE COMPANIES

o India Ltd. GOETZE (India) Ltd.

o GOETZE TP (India) Ltd.

o GOETZE (India) assets management Ltd.

o Escorts securities ltd.

o Escorts Mahle Ltd.

o Escorts Employees Ancillaries Ltd.

o Escorts Finance Ltd.

o IFS India Escorts

o Hughes Escorts communication ltd.

o Carraro (India) ltd.

Page 13: Escorts Training Report Cg

ESCORTS GROUP CORE BUSINESSES

BUSINESS GROUPS PRODUCTS

Agri-Machnary Tractors

Construction equipment Earth moving Machines

Vibratory Rollers

Material Handling Equipments

Automotives Pistons, Piston Rings

Aluminum Cylinders

Shock Absorbers

Carburetors

Magnetos

Clutches

Railways Air Brakes

Couplers

Electro-Pneumatic Brakes

Shock Absorbers

Telecom Cellular Telephone services

VSAT Services (satellite communication system)

Financial Services Automobile Financing

Consumer Finance

Mutual Funds

Fixed Deposits

Manufacturing Facilities Machining

Painting

Assembly

Product Units(Pus) Engine PU

Transmission PU

Rear Axle PU

Assembly/tractor PU

Departments Personnel & HRD

Finance

Manufacturing Engineering

Plant Engineering & Machine Maintenance

Information Systems

Page 14: Escorts Training Report Cg

THE PLANT

The plant is equivalent with the following units:-

Engine Productive Unit (EPU)

Transmission Productive Unit (TPU)

Rear Axle Productive Unit (RAPU)

Tractor Productive Unit (TPU)

Paint Shop

Now transmission productive unit and rear axle productive unit have been merged and now it is

one productive unit known as transmission and rear axle productive unit.

The plant is equipped with the following facilities:-

MACHINE SHOP : EPU, RAPU AND TPU have separate machine shops equipped with

several purpose machine (SPM) as well as Computerized Numerically Controlled (CNC

machine).

The different components machine in these shops with their respective

sections are listed below:

o Cylinder Head, Cylinder Block and Connecting Rod.

o Case Transmission.

o Center Housing & Trumpet Housing.

o Tool Room.

o Turning, CNC, Gear Cutting, Grinding & Heat Treatment.

In heat treatment shop following facilities are available:

o Gas Carbonizing, Hardening & Tempering

o Induction Hardening

Following facilities are available in the various productive units:

o Transmission assembly

o Rear axle assembly

o Engine assembly and testing

o Tractor assembly

Page 15: Escorts Training Report Cg

PROPOSED IDEAS

Before coming to the select final project that is “STUDY AND UPDATION OF PROCESS OF

CLYNDER BLOCK E 3-312”, I had discussed various project ideas.

1. Time Study of process.

2. Inspection sector

3. Inventory and Storage.

Time Study of process

AIM: To study each and every process and find out the time period of each machine and

suggest idea to improve the system.

Reasons for Rejection

i) It Is already given to another group of trainee

Inspection and Instrument

AIM: To Study the inspection Process and study Of Inspection Instrument.

Reasons for Rejection:

i) Source Of Knowledge Is small.

STUDY AND UPDATION OF PROCESS OF CLYNDER BLOCK E 3-312

AIM: To Study the whole process and find out the factors which are help full to improve the

Quality and reduces the process timing.

i) It covers Both “Time Study of Process” and “Inspection and Instrument”.

ii) Scope of Knowledge is more.

iii) It is needed because some Machine are Replace By new Machine and sequence is also

alter.

Page 16: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name DUPLEX MILLING MACHINE (SPM) Machine Number BSM-8

Operation Number 20

Cycle time 7mint

OPERATION DESCRIPTION CUTTING TOOL DETAIL

Rough and finish milling operation on sump face and head face is occur on this machine.

1. HEAD FACE: Rough and semi finish milling operation

2. SUMP FACE: Rough and semi finish milling operation

Face milling cutter

Sump side

Diameter 500mm Insert span 1203 THN/H13A

Head Side

Diameter 400mm Insert span 1203 THN/H13A

Page 17: Escorts Training Report Cg

Process Explanation

Milling: It is a machining process in which the removal of metal takes place due to

cutting action of revolving cutter when the work is fed past it Revolving cutter is on a spindle

or arbour and the work (job), clamped on the machine table, fed past the same In doing so,

the teeth of the cutter remove the metal , in the form of chips from the surface of the work to

produce the desire shape.

DUPLEX MILLING MACHINE (SPM)

PROCESS:

This is a special purpose machine (milling).

In this machine only face milling operation occur.

Milling Operation occurs on head face and sump face.

The whole process is occurs in reference of DOWEL as shown in the diagram.

Reference of work piece also known as dowel

Page 18: Escorts Training Report Cg

BRIEF DISCUSSION OF MILLING OPERATION

Milling is a basic machining process by which a surface is generated by progressive chip removal.

The work-piece is fed into a rotating cutting tool. Sometimes the work-piece remains stationary, and

the cutter is fed to the work. In nearly all cases, a multiple-tooth cutter is used so that the material

removal rate is high.

Often the desired surface is obtained in a single pass of the cutter or work and, because very good

surface finish can be obtained, milling is particularly well suited and widely used for mass-production

work. Many types of milling machines are used, ranging from relatively simple and versatile

machines that are used for general-purpose machining in job shops and tool-and die work (these are

NC or CNC machines) to highly specialized machines for mass production. Unquestionably, more flat

surfaces are produced by milling than by any other machining process.

Process Explanation:

Milling operations can be classified into two broad categories called peripheral milling and face

milling. Each has many variations. In the surface is generated by teeth located on the periphery of the

cutter body. The surface is parallel with the axis of rotation of the cutter. Both flat and formed

surfaces can be produced by this method, the cross section of the resulting surface corresponding to

slab milling, the axial contour of the cutter. This process, often called is usually performed on

horizontal spindle milling machines. In slab milling, the tool rotates at (Ns) fm some rpm while the

work feeds past the tool at a table feed rate in mm per ft. minute, which depends on the feed per tooth,

V As in the other processes, the cutting speed and feed per tooth are selected by the engineer or the

machine tool operator. As before, these variables depend upon the work material, the tool material,

and the specific process. The cutting velocity is that which occurs at the cutting edges of the teeth in

the milling centre. The rpm of D the spindle is determined from the surface cutting speed, where is the

cutter of diameter in [mm] according to: Ns = 1000 V/ p D

Page 19: Escorts Training Report Cg

UP VERSUS DOWN MILLING

For either slab end or face milling, surfaces can be generated by two distinctly different

methods. Up milling is the traditional way to mill and is called conventional milling. The

cutter rotates against the direction of feed of the work-piece. In climb or Down milling, the

cutter rotation is in the same direction as the feed rate. The method of chip formation is

completely different in the two cases.

In up milling, the chip is very thin at the beginning where the tooth first contacts the work,

then it increases in thickness, becoming a maximum where the tooth leaves the work. The

cutter tends to push the work along and lift it upward from the table. This action tends to

eliminate any effect of looseness in the feed screw and nut of the milling machine table and

results in a smooth cut. However, the action also tends to loosen the work from the clamping

device; therefore, greater clamping forces must be employed with the danger of deflecting the

part. In addition, the smoothness of the generated surface depends greatly on the sharpness of

the cutting edges. In up milling, chips can be carried into the newly machined surface,

causing the surface finish to be poorer (rougher) than in down milling.

In down milling, maximum chip thickness occurs close to the point at which the tooth

contacts the work. Because the relative motion tends to pull the work piece into the cutter,

any possibility of looseness in the table feed screw must be eliminated if down milling is to

be used.

It should never be attempted on machines that are not designed for this type of milling.

Page 20: Escorts Training Report Cg

Virtually all modern milling machines are capable of doing down milling and it is a most

favorable application for carbide cutting edges. Because the material yields in approximately

a tangential direction at the end of the tooth engagement, there is less tendency (than when up

milling is used) for the machined surface to show tooth marks, and the cutting process is

smoother with less chatter. Another advantage of down milling is that the cutting force tends

to hold the work against the machine table, permitting lower clamping forces. However, the

fact that the cutter teeth strike against the surface of the work at the beginning of each chip

can be a disadvantage if the work-piece has a hard surface, as castings sometimes do. This

may cause the teeth to dull rapidly. Metals that readily work harden should be climb milled.

MILLING TOOLS AND CUTTERS

A rotary tool-steel cutting tool with peripheral teeth, used in a milling machine to remove

material from the work-piece through the relative motion of work-piece and cutter .

Page 21: Escorts Training Report Cg

Basic Operation:

Page 22: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name Part Number D10025590B

Machine Name HTC-630 & HTC 600 (SPM)

Machine Number BMC-8 & BMC-16

Operation Number 30

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS 1. HEAD FACE

Finish milling operation 2. SUMP FACE

Finish milling Drilling – Hole milling-Reaming

of dia. 13H7 of 2 dowel Drill Dia. 18.5 Drill two holes on L-pad of

Dia.10.2 3. CAP SEAT

Rough / finish milling operation

1.T-Max Face milling cutter Radius 265.4-125-10 2.C.T. Milling Cutter 3.HSS T.S. Drill Tool of dia. 12mm 4.S.S. Hole Mill Tool of Dia. 12.7mm 5 Reaming Tool of Dia. 13H7

Page 23: Escorts Training Report Cg

BRIEF DISCUSSION OF DRILLING OPERATION

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 work piece and rotated at rates from hundreds to thousands of revolutions

per minute. This forces the cutting edge against the work piece, cutting off chips from what

will become the hole being drilled.

Classification of Drill:

Drills are manufactured in several different forms and sizes. They commonly used drills can

be classified in many ways, as follows:

1. According to the type of shank they carry:

a) Parallel shank

b) Taper shank

2. According to the type of Flutes :

a) Flat or Spade drills (parallel longitudinal flutes)

b) Twist Drills (spiral/ helical flutes)

3. According to the Tool Material:

a) High Speed Steel Drills

b) Carbide Tipped Drills

When inspecting various products around us we realize that the vast majority have several

holes in them. Holes are generally used either for assembly with fasteners such as bolts

screws and rivets each requiring a hole or to provide access to the inside of a part. Note for

example the number of rivets on an airplane s fuselage or the bolts in engine blocks and

various components under the hood of an automobile.

Hole making is among the most important operations m manufacturing. In automotive engine

production the cost of hole making is one of the largest machining costs. Drilling is a major

and common hole making process other processes for producing holes are punching and

various advanced machining processes.

Because drills usually have a high length-to-diameter ratio the next figure they are capable of

producing relatively deep holes. They are somewhat flexible however depending on their

diameter and should be used with care in order to drill holes accurately and to prevent the

drill from breaking.

Page 24: Escorts Training Report Cg

TYPES OF TOOL

Furthermore the chips that are produced within the work-piece have to move in the direction

opposite to the axial movement of the drill. Consequently chip disposal and the effectiveness

of cutting fluids can present significant difficulties in drilling.

Generally the hole diameters produced by drilling are slightly larger than the drill diameter

oversize as one can note by observing that a drill can be easily removed from the hole it has

just produced. The amount of oversize depends on the quality of the drill and of the

equipment used as well as on the practices employed. Depending on their thermal properties

some metals and non-metallic materials expand significantly due to the heat produced by

drilling so the final hole could be smaller than the drill diameter .Also drilled holes may be

subjected to subsequent operations for better surface finish and dimensional accuracy such as

reaming and honing. Drills generally leave a burr on the bottom surface upon breakthrough

necessitating de-burring operations.

TWIST DRILL

The most common drill is the conventional standard-point twist drill Fig. (a) the main

features of which are the point angle lip-relief angle chisel-edge angle and helix angle. The

geometry of the drill tip is such that the normal rake angle and velocity of the cutting edge

vary with the distance from the center of the drill.

Page 25: Escorts Training Report Cg

Generally two spiral grooves flutes run the length of the drill and the chips produced are

guided upward through these grooves. The grooves also serve as passageways to enable the

cutting fluid to reach the cutting edges. Some drills have internal longitudinal holes through

which cutting fluids are forced improving lubrication and cooling as well as washing away

the chips.

Drills are available with a chip-breaker feature ground along the cutting edges. This feature is

important in drilling with automated machinery where disposal of long chips without operator

assistance is necessary.

Other Types of Drills.

Several types of drills are shown in the next figure.

A step drill produces holes of two or more different diameters. A core drill is used to make an

existing hole larger. Counter-boring and countersinking drills produce depressions on the

surface to accommodate the heads of screws and bolts. A center drill is short and is used to

produce the hole at the end of a piece of stock so that it may he mounted between centers in a

lathe between the headstock and the tailstock. A spot drill is used to spot to start a hole at the

desired location on a surface. Spade drills have removable tips or bits and are used to produce

large and deep holes. They have the advantages of higher stiffness because of the absence of

flutes in the body of the drill ease of grinding the cutting edges and lower cost. Crankshaft

drills have good centering ability and because chips tend to break up easily these drills are

suitable for producing deep holes.

Page 26: Escorts Training Report Cg

Twist Drills

Twist drill is the most widely used in the modern drilling practice. It consist of a cylindrical

body carrying two spiral flutes cut on it.

Parts of Twist Drill

Three main components are the:

Shank

Body

Point

1. SHANK

This is the portion which is “clamped” to provide the drive. Straight shank for

drill up to ½” . Shank is equal to body diameter. Above ½”, shank can be

tapered or reduced.

2. BODY

a) Flutes - Helical grooves cut around the body which form the cutting edges

Allow coolant to flow to the cutting edge

Allow chips to be withdrawn

b) Margin- Narrow raised section of the body. Provides full body to hole support

to help keep it aligned as it drills.

c) Body clearance - Reduced section of the drill between the flutes and margin.

Used to reduce friction between drill and workpiece

d) Web- Thin section in the center of the drill which forms a “core” for the drill.

This feature increases as it extends to the shank. Forms the chisel edge of the

drill.

3. POINT - Chisel edge of the drill.

a) Lips

b) Cutting edges

Page 27: Escorts Training Report Cg

DRILLS MATERIALS

The two most common types are

1) HSS drills

i) Low cost

2) Carbide-tipped drills

ii) High production and in CNC machine

Other types are

Solid carbide drill, Tin coated drills, carbide coated masonry drills, parabolic drills, split point drill.

Page 28: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name Part Number D10025590B

Machine Name HTC-600 & Yasda (SPM)

Machine Number BMC-11

Operation Number 40

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS 1. NAME PLATE SIDE

Rough/ Finish Milling Drill/TAP of M-14

2. TAPPET COVER SIDE (TCP) Rough/Finish Mill Rough/Finish Bore of Dia.36H8

(3 holes) 3. TIME GEAR SIDE (TGC)

Mill Water impeller seat Drill of Dia. Ø 5

1. STD Facing Milling Cutter R 265.4

2. End Milling Tool of dia. 40mm & 50mm

3. STD H.S.S T.S. Drill of dia.5*8

4. Finishing Bore Bar of dia. 36H8.

5. Finishing Bore Bar of dia. 36H8.

Page 29: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name CNC DUPLEX MILLING (BM-211)

Machine Number BSM-11

Operation Number 50

Cycle time 6 Minute

PERATION DESCRIPTION CUTTING TOOL DETAILS

TIME GEAR SIDE a)Rough/finish mill

BELL HOUSING SIDE a) Rough/finish mill

TIME GEAR SIDE (UNIT A)

a) STD Centring plug ISO 50 x Ø60 500 cutter (widia number 80504021)

b) Face milling cutter Ø 500 BELL HOUSING SIDE (UNIT-B)

a) STD Centring plug ISO 50 x Ø60 500

cutter (widia number 80504021) b) Face milling cutter Ø 500

Page 30: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name WEB & NTCH MILL (BM-147)

Machine Number BSM-6

Operation Number 60

Cycle time 6 Minute

PERATION DESCRIPTION CUTTING TOOL DETAILS

Plunge mill web thickness & 4 notches on cap seat

TEF-2545 milling arbour TEF 2486 HSS notch milling cutter Ø80

x Ø40H x 5D11 TEF-2490 of spacers TEF half side and Face milling cutter RH-

hmt No. ( ) TEF half side face milling cutter L.H.-

hmt No. BM-147-9401-39

Page 31: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name OIL GALLERY SPM(M348) Machine Number BSD-13

Operation Number 70

Cycle time 7:00 MINT

PERATION DESCRIPTION CUTTING TOOL DETAILS

Drill oil gallery hole from Crank to Cam bore of Ø9 x Ø 7- 4 holes.

Drill from Crank to Idler Bore of Ø 6.8–1 hole.

Drill hole on Sump face of Ø15 – 1 hole Drill holes on Tappet cover side of Ø 9–

4 holes A drill on Head face side of Ø 7 – 1 hole

H.S.S. T.S. Drill Ø 15x 350FL x 450 OAL (M35)TIN coated MT-2

H.S.S. Drill Ø 6.8 x 195FL x 250OAL (M35) tin coated MT-1

H.S.S. TS drill Ø 7 x 300FL x 350OAL

(M35) Tin coated MT-1

H.S.S. TS Drill Ø 9 x 195FL x 295OAL (M35) Tin coated MT-1

Page 32: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name SNCH-11 & HMC-5008

Machine Number BMC-7 & BMC-9

Operation Number 120

Cycle time 28.8/25.5

PERATION DESCRIPTION CUTTING TOOL DETAILS

BELL HOUSING SIDE Drill Oil Gallery Of Ø 14

TAPPET COVER SIDE Drill/Tap M10-6 hole, M12-3hole, Drill of Ø14-1 hole.

NAME PLATE SIDE Drill of Ø 12.5 hole

.

STD twist Drill Ø14 x 410 OAL MT-1 STD twist Drill Ø14 x 223 OAL MT-1 STD Drill Ø9 x 175FL x 275OAL MT-1 STD Drill Ø 11 (MT-1) STD Drill Ø10, Ø12, Ø12.5

Page 33: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name HEAD FACE DRILL(E-363)

Machine Number BSD-14 ALT:- RADIAL DRILL

Operation Number 90

Cycle time 4.10 MINT

PERATION DESCRIPTION CUTTING TOOL DETAILS

HEAD FACE Drill Ø 12-14 holes Drill Ø14.5-2holes Drill Ø18.5-2 holes Drill Ø 12-14 holes Drill Ø 14.5-14 holes Drill Ø5-4 holes

STD T.S. Twist Drill Ø12h8 x 225 OAL (Tin coated with M35 HSS material )

STD Core Drill Ø14.5 x 212OAl (Tin coated with M35 material)

STD Core Drill Ø 18.5-233OAL ALT Drill

STD Core Drill Ø14.5 MT-2 STD Drill Ø5

Page 34: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name 2 WAY MULTIDRILL SPM (Y-1643)

Machine Number BSD11

Operation Number 100

Cycle time 2.23

PERATION DESCRIPTION CUTTING TOOL DETAILS

TIME GEAR SIDE Drill Ø6.8-17 holes Drill Ø14-4 holes Drill Ø7-1 holes Drill Ø8.5-2 dowel

BELL HOUSING SIDE Drill Ø10.2-10 holes Drill Ø12-2 holes

STD H.S.S. Twist Drill Dia. Ø 10.2 x 116FL x 197OAL Dia. Ø9 x 107FL x 188OAl

STD H.S.S. T.S Twist Drill (MT-1) Dia. Ø14 x 108FL x 189 OAL Dia. Ø12 x 101FL x 182 OAL

TET-2272 H.S.S. S.S. Twist Drill Ø6.8 x 156OAL

TET-6367 H.S.S. S.S. Twist Drill Ø7 x 156OAL

Page 35: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name Part Number D10025590B

Machine Name MULTIDRILL SPM (MD-419)

Machine Number BSD-10

Operation Number 110

Cycle time 5:00 MINT

PERATION DESCRIPTION CUTTING TOOL DETAILS

SUMP FACE Drill of Ø 8.5- 10 holes

CAP SEAT FACE Drill Ø 14 & Counter Drill Ø16.5-8 holes

HEAD FACE Tap M14-12 Holes

STD H.S.S. TS Twist Drill Ø6.5 x 181 OAL MT-1

STD H.S.S. TS Twist Drill Ø14 x 223 OAL MT-2

STD H.S.S. TS Twist Drill Ø 16.5 x 223 OAL MT-2 Alternate

STD H.S.S. TS Drill Ø16.6 x 223 OAL MT-2

Page 36: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name TAPPING MACHINE(RADIAL DRILL)

Machine Number BTM-1

Operation Number 130

Cycle time 14:00 MINTS

PERATION DESCRIPTION CUTTING TOOL DETAILS

SUMP FACE Tap M10-10 holes Tap M20-1 hole L-pad Tap M12-2 holes

TIME GEAR SIDE Tap M8-19 holes Tap M16-4 holes Dia.5-1 hole

BELL HOUSING SIDE Tap M12-10 holes

STD Machine Tap M10 x 1.5 Type C M12 x 17.5 Type C M16 x 2 Type C M20 x 1.5 Type C M8 x 1.25 Type C M14 x 2 Type C

Page 37: Escorts Training Report Cg

Part Name

Part Number D10025590B

Machine Name Air Cleaning & Cap Fitting

Machine Number

Operation Number

Cycle time

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

PERATION DESCRIPTION CUTTING TOOL DETAILS

Simple Machine working

Page 38: Escorts Training Report Cg

Part Name

Part Number D10025590B

Machine Name Rough Boring SPM

Machine Number BSB-6

Operation Number 140

Cycle time 10.75

PERATION DESCRIPTION CUTTING TOOL DETAILS ROUGH BORE OF

a) Crank bore b) Cam bore c) Idler bore.

TFE-6091 Boring Bar for Crank Bore. TET-2259 T-max Facing Tool L-H TET-2260 T-max Facing Tool R-H TEF-6092 Boring Bar for Can Bore STD-T Max Cartridge R437-9-1214-11 STD- T Max Insert TPUN 110308-H20 TEF-6341 Boring Bar for Idler Bore Insert TPMR 160308X10 CHF INSERT CCMT 060204 UR UNIT-B(BHS) TEF-6094 Boring Bar Crank Bore STD T max Cartridge R437.9 – 1320.16 STD T max Insert TPUN160308-H-20 TEF-6095 Boring Bar for LAN Bore

Page 39: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name Lime Boring SPM(YB017& Y3304)

Machine Number BSB-5

Operation Number 150

Cycle time 4-9 Min

PERATION DESCRIPTION CUTTING TOOL DETAILS

FINISHED / SEMI FINISHED BORE OF

a) Crank Bore b) Cam Bore c) Idler Bore

TET-9180 Boring Bar for Crank Bore TET-3244 Boring Tool STD T-Max Catridge R-437.9-1214.4 STD T-Max Insert TPUN 110308 HIP TEF-3237 Boring Bar for Cam Bore TET-3242 Boring Tool STD T-Max Cartridge 1-1481-11-0602 STD T-Max Insert CCMT 060204-41p TEF 6200 Boring Bar for Idler Bore STD Micro Bar Unit M3A2F40

Page 40: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name Lime Boring SPM(Y3304)

Machine Number BSB-8

Operation Number 180

Cycle time 4.46 Min

PERATION DESCRIPTION CUTTING TOOL DETAILS

BORE OF

a) Sank Bore b) Cam Bore c) Idler Bore

TEF-3395 Boring Bar for Crank Bore STD T-max U Fine Boring Unit L-148C-13-1102 STD Insert TCMT 110208 HIP TEF-3237 Boring Bar for Cam Bore STD T-max U Fine Boring Unit L-148C-13-D602 STD Insert CCMT 060208 HIP ALT-CCGX 060204 Grade ALH-10 TEF-6200/1 Boring Bar for Idler Bore STD T-max U Fine Boring Unit L-140C-31-0602 STD Insert CCMT 0602084P

Page 41: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name Dowel Hole SPM

Machine Number FB-668 (BS7-9)

Operation Number 200

Cycle time 3.35 Min

PERATION DESCRIPTION CUTTING TOOL DETAILS

BELL HOUSING SIDE Bore Dia. Ø -13h7-2 Dowel Holes.

Hole Mill/Ream Dia. 13h7-2 Dowel Holes.

TIME GEAR SIDE Bore Dia. Ø -10h7-2 Dowel Holes. Hole mill/Ream Dia. 10H7-2 Dowel Holes.

TEF-6529 Tool Holder For Dia-13H7 TEF-6500 Boring Bar For Dia-13H7 TEF-6542 Tool Holder For Dia. 10H7 TEF-6449 Boring Bar For Dia. 10H7 TEF-6523 Locating PIN for B.H.S. Insert STD CCMT 060204 THM TEF-6524 Locating PIN for T.G.S. ALTERNATE On Radial Drill STD Collect MT-1 For Q.C.C STD H.S.S Reamer Dia-10H7 15.5445 TET-2053 H.S.S H Mill Dia. 12.7H9 STD H.S.S Reamer Dia. 13H7 155445

Page 42: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name Tappet-SPM (Y-3505)

Machine Number BSD-16

Operation Number 190

Cycle time 8:00 Min

PERATION DESCRIPTION CUTTING TOOL DETAILS

End Mill Drill Hole Mill Ream – 24H8-6 Tappet Hole

TET-6671 JIG Bar For Drill 22.5 TET-6620 End Mill 36 x 65FL x 157OAL MT-3 TET-6672 JIG Bar For Hole Mill

Page 43: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name VTC-3 & VTC-5

Machine Number

Operation Number

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS

Drill Oil dip stick hole. Drill/Tap M8-2 holes Time Gear Side. thru Hole Mill/Ream dia.18H8-2.

STD Tap Driver for M8(MT-2) STD Machine Tap M8 x 1.25 Type 'C'.

Page 44: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name VCRT MACHINE G CENTER(LMV55)

Machine Number

Operation Number

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS

Finish milling head face. Finish Bore linear Bore. Hole Mill/Ream Dia.20H8-2 Dowel Holes. Drill Dia. 10-3 Holes.

Page 45: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name Part Number D10025590B

Machine Name INSPECTION AND CLEANING

Machine Number

Operation Number

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS

INSPECTION PLACE

CLEANING MACHINE

Page 46: Escorts Training Report Cg

ESCORTS LIMITED COMPONENT PLANT CASTING AREA

Part Name

Part Number D10025590B

Machine Name MANUAL BUSH PRESSING MACHINE

Machine Number

Operation Number

Cycle time

PERATION DESCRIPTION CUTTING TOOL DETAILS

Fit 4 Cam Bush .

Bush

Page 47: Escorts Training Report Cg

OPERATION FINAL INSPECTION

S.NO. DISCRIPTION DIMENTION INSTRUMENT GAUGE

1. Tappet Bore Dia. 24H7 Dial Bore Gauge STD

2. 3-Holes on Tappet Cover side 36H8 Dial Bore Gauge STD

3. Cam Bore Dia. 56H7 Dial Bore Gauge STD

4. Thrust Bearing Dia. 110+0.12 Plate Gauge TEG-3249

5. Thrust Face Thickness 42(-.02or-.009) Width Gauge TEG-2250

6. Alignment of Cam Bore 0.02 Mandrel TEG-6244

7. Crank Bore Dia. 91.055/91.085 Dial Bore Gauge STD

8. Alignment of crank Bore 0.02 Mandrel TEG-6202

9. Idler Bore Dia. 32H7 D.B.G. STD

10. Dia. of Linear Bore 120H7

121H7

130H7

Dial Bore Gauge STD

11. Depth of C'Bore From Head Face 11(+0.02) Flush pin Gauge

width Dial

TEG-6265

12. Position of Crank, Cam, Idler Bore Depth

Of Thrust Face position of linear bore

Gauging fixture TEG-6046

13. Linear Bore Stud Hole Clearance Functional Gauge TEG-6393

Page 48: Escorts Training Report Cg

TECHNICAL CONDITIONS

All oil galleries to be checked with dia.3mm wire for through

holes.

All oil galleries to be cleaned and blown through by air under

pressure.

Water impeller seat to be checked for fouling of impeller with

side walls.

Check all liner bore for fouling of linear will wall.

Check all Threaded holes for threading depth.

Page 49: Escorts Training Report Cg

ISHIKAWA CHART

Diagnose the cause of failure of Cam, Crank, Bore .

Page 50: Escorts Training Report Cg

CONCLUSION

Its give me better honour and privilege to conclude the Project report on “

STUDY AND UPDATION OF PROCESS OF CLYNDER BLOCK – E 3-312”

has been presented in a very concise and lucid manner i indeed have given

commitment to the development of my project.

The aim STUDY AND UPDATION OF PROCESS is to get knowledge of all

process occurs in this cylinder block.

This project help me out to get a lot of information not only the processes occur

in this line but also different fields like inspection and quality control unit and it

also tell me the human relationship which is needed in Between managers, team

leaders and employ of the company.

It also help me to get knowledge about the tools and there different-different

properties and types.

Some new things which i learned from this company are

Use of different –different gauges.

How to inspect the job after each and every inspection

How to manage the machine if there is any problem arises in the machine

Tools specification and its inserts characteristics.

How to manage the task in the given interval of time.

.

Page 51: Escorts Training Report Cg

THANKYOU