SIXTH MONTH INDUSTRIAL TRAINING PROJECT REPORT

ESCORTS INDIA PVT. LTD. Crank Shaft & Hydrolic Plant GROUP, FARIDABAD

METHODS INVOLVED IN THE PROCESS OF PRODUCTION OF REAR AXLE

Project Head Mr. Sukhpal Sir

Prepared By : ` Sushil Kumar Roll No. - 100390593941 B-tech – Electrical

GURU RAM DAS ENGINEERING COLLEGE, LEHRA BEGHA

CONTENTS

 ACKNOWLEDGMENT  PREFACE  THE SYMBOL OF ESCORT  ESCORTS PROFILE  INTRODUCTION  The Founding Philosophy  Background  ESCORTS:RESTRUCTURING  AGRI-MACHINERY GROUP  TRACTOR M/C SHOP(PLANT 1)  Overview – Manufacturing  Overview – Material Management  Methods Involed  Design  SHAFT HYDRAULIC LIFT ARM FACING AND TURNING ROUGH TURNING FINISH TURNING DRILLING HOBBING ROLLING WELDING GRINDING HARDENING AND TEMPERING INSPECTION

Acknowledgement

I would like to thank to all those with whom I worked and whose thoughts and insights helped me in increasing my knowledge and understanding of working in the organization.

I would like to pay my sincere gratitude to MR. SUNIL SANDHU & all employees, my project guide, who helped me during the course of my training by providing his valuable suggestion, ideas and guidance which proved beneficial for completion of my project.

Besides I would also thank to all the supervisors, Foreman and workers who helped me to understand the depth of my project, what they want out of the project.

These people made me comfortable to understand the functioning of each machine & about the operation occuring on the machines. They tried their best to make me understand about the fixtures, tools and gauges used on the machine. These peoples never made me feel as a trainee in the department rather provide an atmosphere like a family and feel proud being the part of their through for short while. Without their help this project would never have taken its present form. In fact this project is the result of their vision, optimistic and encouraging attitude.

In the end I would like to thank the ESCORTS AGRI MACHINERY GROUP for providing me with this brilliant opportunity to understand the working of an industry and developing my technical aptitude.

PREFACE

Industrial training now a days one & the only one method to make students familiar with the modern techniques, latest equipments & methods used in various industries. During industrial training, students visit to various companies and make themselves familiar with the practical aspect of the production method.

This training has provided and ultimate experience& opportunity to have practical knowledge which has increased my level of thinking and dealing with different kinds of people in all walks of life. It helps us a lot while appearing to the interviews. Industrial training in proves the theoretical and the practical concept of the student about engineering.

The well planned, properly executed & evaluated industrial training helps a lot in inculcating good work culture. It provides linkage between the students & the industries in order to develop and awareness of industrial approach to problem solving based on broad understanding of plant.

HISTORY OF MOTOR CYCLES

A motor cycle is a vehicle in which the principle of bicycle and internal combustion engine are combined. The internal combustion engine generally in a gasoline engine, the term covers a range of machine from 50cc, piston displacement tor bellow 9mopeds or motor cycle) to 1000 cc multiple cylinder models of which the US HARLEY DAVIDSON and Indian V. TWENS, the british 10000cc. square four aerial and the 4 cylinders. Italian M.V. AUGUSTA representative the term motor cycle also cover motor which have until from 50cc to 250cc.

An Englishmen, Edward butter, built the first motor cycles in 1884, but the first motor cycle to appear publicity was on built by ‘Goltlied Damier” of cons tract, Wuthembua of Germany in 1885. Motor cycle did not attain even slight public popularity until towards the end of 19th century. French and Belgium designers and manufactures and use of motor cycle increasing steadily throughout first 30 year of the 20th century. In both world wars, motor cycle, were widely use for military purpose and after world war second, an appreciation of the value of two-wheeler laid the foundation for the remarkable revival of public interest in motor cycle, and scooters, in the united states the years after the world war 2nd witnessed a revival of interest that could be compare with the western Europe.

[ Development of machines:

The development of motor cycle users study in tech formative years positioning of the power unit varied but by 1910 designing has recognized that the most practical point was low and central, later engine units were carried in twin tubs card less were build up from tubing joined by either welding or brazing.

Early single colander commercial motor cycle persistence in the second half of the 20th century. Most models of than 250cc were four stroke in which value we employed with the compression firing in one direction (upward or downward) only many bellow else capacity were two strokes, compression firing being on both strokes through a succession of passenger wall and parts, the European method of ration an engine is by the volumetric displacement of the position in cubic centimeter.

Evolution of Two-wheeler Industry in India:

Two-wheeler segment is one of the most important components of the automobile sector that has undergone significant changes due to shift in policy environment. The two-wheeler industry has been in existence in the country since 1955. It consists of three segments viz. scooters, motorcycles and mopeds. In India there are some MNC’s and Indian company dealing in automobile sector. The main key players who are dealing in this sector are Hero , Bajaj, Yamaha, Honda, and TVS. Hero Honda is the biggest player in this sector in India as well as in the world and playing a very important role in two wheeler automobile sector. Hero Honda, Bajaj and TVS are the Indian companies and Yamaha & Honda are international automobile brand.

Bajaj is the first Indian two wheeler automobile company in the market since 1945 with the name M/s Bacharj trading corporation private limited. In 1959 M/s Bacharj trading corporation private limited change its name as Bajaj Auto Ltd. Bajaj Auto obtains license from the Government of India to manufacture two- and three-wheelers vehicles in 1959.

Hero Honda Motors Limited was established in 1984, as a joint venture between India's Hero Group (world's largest bicycle manufacturers) and Japan's Honda Motor Company. And created the world's single largest two wheeler company and also one of the most successful joint ventures worldwide. During the 80s, Hero Honda became the first company in India. Over 19 million Hero Honda two wheelers running on Indian roads today.

TVS Motors is the third largest company in the two-wheeler industry with a market share of 16%. Infect, it is the only Indian company without a foreign collaboration in the two- wheeler industry. When the company opted out of the collaboration with Suzuki in 2002, many believed that TVS was headed towards extinction. But the company proved the doomsayers wrong and came out with a very successful `TVS Victor'. TVS Motors Ltd. originally incorporated in 1982 to manufacture two-wheelers in collaboration with Suzuki Motors of Japan, TVS was one of the leaders in two-wheeler industry.

Yamaha Motor Corporation is the auto mobile company of Japan (1953) which works in India since 1955 and providing latest technology in India from last two decades. Yamaha Motor India was incorporated in august 2001 as a 100% subsidiary of Yamaha motor corporation, Japan

Honda motors of Japan is not a new name in the two wheeler scenario in the country, they were in a tie up with the Firodias owned Kinetic group. However in the late 90s they parted ways after problems arose over issues like introduction of new models, advertising expenditure, marketing strategies and other related issues. In the mid 80 Honda motors of Japan joined hands with the largest bicycle maker of India the Hero cycles to create Hero Honda which in a couple of decades or so have gone on to become the single largest motorcycle company in the world. Though Honda has come on its own on the Indian market yet it will be providing technological support to Hero Honda for the next ten years. Thus presenting a unique situation in which the company will be in direct competition with the company which it has been associated for nearly two decades. Honda Motorcycles and Scooters India limited, a 100% subsidiary of Honda motor company Japan eventually entered the Indian market with Honda Unicorn in 2004.

ORGANISATIONAL PROFILE

Introduction:

Honda is the world's largest manufacturer of 2-wheelers. Its symbol, the Wings, represents the company's unwavering dedication in achieving goals that are unique and above all, conforming to international norms. These wings are now in India as Honda Motorcycle & Scooter India Pvt. Ltd. (HMSI), a wholly owned subsidiary of Honda Motor Company Ltd., Japan. These wings are here to initiate a change and make a difference in the Indian 2-wheeler industry. Honda's dream for India is to not only manufacture 2-wheelers of global quality, but also meet and exceed the expectations of Indian customers with outstanding after sales support.

They are world leaders in motorcycles and also pioneer in four-stroke technology. It has manufacturing operations in 32 countries with 109 productions bases. They have collaborators and technical ties their own subsidiary. Before Honda came to India they made a survey of a two wheeler market, which was dominated by bullet and yezdi motor cycles, which were old technology and also with an outdated, look during time, Honda motor company ltd realized there was a huge demand for technically advanced fuel efficient, lighter machines. In addition to this, their study also revealed poor public transportation at an economical and affordable price of having personal mode of transportation at an economical and affordable price was need pf the hour. Hence, Honda motor company ltd established its own manufacturing unit in India.

Honda Motor Co., Ltd. operates under the basic principles of "Respect for the Individual" and "The Three Joys" — commonly expressed as The Joy of Buying, The Joy of Selling and The Joy of Creating. "Respect for the Individual" reflects our desire to respect the unique character and ability of each individual person, trusting each other as equal partners in order to do our best in every situation. Based on this, "The Three Joys"

Expresses our belief and desire that each person working in, or coming into contact with our company, directly or through or products, should share a sense of joy through that experience. In line with these basic principles, since its establishment in 1948, Honda has remained on the leading edge by creating new value and providing products of the highest quality at a reasonable price, for worldwide customer satisfaction. In addition, the Company has conducted its activities with a commitment to protecting the environment and enhancing safety in a mobile society.

The Company has grown to become the world's largest motorcycle manufacturer and one of the leading automakers. With a global network of 454 subsidiaries and affiliates accounted for under the equity method, Honda develops, manufactures and markets a wide variety of products, ranging from small general- purpose engines and scooters to specialty sports cars, to earn the Company an outstanding reputation from customers worldwide.

Honda Motorcycle & Scooter India PVT Ltd:

Honda Motorcycle & Scooter India, Private Limited (HMSI) is the wholly owned Indian subsidiary of Honda Motor Company, Limited, Japan.[1] Founded in 1999,[1] it was the fourth Honda automotive venture in India, after Hero Honda, Kinetic Honda Motor Ltd and Honda Siel Cars India Limited.. The entry of Honda into the Indian market as HMSI began with the launch of the , a 100cc scooter. A slightly modified trendier version of the Activa was soon launched, as the . Honda Eterno was launched thereafter to add to the portfolio of HMSI's scooters. The Honda Unicorn was the first motorcycle released by HMSI. The Honda Shine has since been released.

A company was international market and when the sales were zooming the annual sales of the company was 86.507$ and with the production capacity of 3.6 million vehicles per year. Here they manufacture both scooters and bikes. Its manufactory vehicles in India re UNICORN, ACTIVA, DIO, ETERNO. Now company is planning to introduce new 125cc bike named SHINE.

They started sponsoring motor rallies, and motor cross this company finance their own manufactured products. Their dealers are the authorized person to deal with finance for their regions.

Honda Company Limited network all over the country sales service and spares. It is a highly technological basically company. All the machines of products are Japanese model. Only Japanese technology and spares are used in their two wheelers. About us Honda

 Official Name : Honda Motorcycle & scooter India Pvt. Ltd

 Established : 20th Aug. 1999

 Place : Manesar, District Gurgaon Haryana India

(New-Delhi)

 Investment : Rs. 300 Crore

 Representative : Mr. Shinji Aayama, President & CEO

 Factory location : Manesar, District Gurgaon Haryana India.

 Production capacity: 10, 000, 00 units per year.

Organization Structure

Product Range:

1. HONDA ACTIVA: Designed for every one

Honda activa is the large Activa selling scooter in India. The 80% sale of Honda two wheeler belongs to HONDA Activa. It is designed for all category and all age people so it has a good demand in market. It is a power of scoter of 102 CC with a 6 ltr. Tank capacity. It has a specialty Manufacturer Honda Motors Ltd. like tuff up tube, electrical start, Production 2004-present space under seat box multi reflector Price Rs. 40661 light etc. Engine 4-stroke, air cooled,7 bhp @ 7000 rpm,102 cc

2. DIO One look at the DIO will tell you it’s more an accessory than a mere Dio convenience as India’s first motor scooter. It blends the look of motor cycle with the comfort of scooter. The body mounted hand lamp and sleek indicator leap right of the front.

Ample legroom gives you an elegant poise. The body tapers into the tail Manufacturer Honda Motors Ltd. light and at continue to draw Production 2004-present attention of course, this quality us to Price Rs. 40136 have the last world on style. If there Engine 4 – ever existed an attention magnet, the Stroke,7bhp@7000rpm,102cc DIO is it.

3 ETERNO

Eterno

Manufacturer Honda Motors Ltd.

Production 2004-present Price Rs.36526

Engine 4-stroke,6.0 KW (8.2 bhp) @ 6000 rpm,147.7 cc

4. SHINE DISK Shine Disk

Manufacturer Honda Motors Ltd.

Production 2004-present

Price Rs 47983

Engine 4-Stroke,10.3 bhp @ 7500 rpm,124.6 cc

5. HONDA CB UNICORN

The Honda UNICORN was first Unicorn Electric Start introduced in SONA MOTORS, Shimoga at 2004. This is a style bike. This is Japanese technology Model bike. This is introduced by HONDA Company Limited. This is the first diamond shaped technology bike and very comfortable bike. This bike is and jested b over drive and business standard Motoring. Manufacturer Honda Motors Ltd. Production 2004-present

Price Rs. 50000-53000 Honda Unicorn is the first Tuff up tube Engine 4 Stroke,13.3 bhp / 9.9 kW and MONA SUSPENSION used bike of the India @ 8000 rpm,149.1 cc it is a Powerful economical and stylish bike of this bike is Manufacture by taking in the mina of both college student and officials its suits both category people because of its power and unbeaten style.

It is stylish and powerful bike of the year. CB UNICORN is the product of HONDA Company Ltd. It is a 149. 1 cc engine, having speed gear, 4 stroke engine first time in India available in the electrical starter as a separate model. However the added auto decompression gives on easy kick-start always. This is No. 1 choice of the youth.

This is the 149.1 cc with 4 stroke air cooled OHC single cylinder engine with mileages of 60 KMPL (In Indian mode) this is one of the India most a prestigious tribute to a technologically superior bike. This is a twin advantages by feature totally the choice one bike of the years. This bike is very powerfully it can reach 60 KM Speed with in a 5 fraction of seconds. This bike have a facility of the self starter and full up table so it is very rush free bike so it is bike of demo.

Technological specification:-

WEIGHT AND MEASUREMENT

Kerb Weight - 139 Kegs (Kick)

142 Kg (Self)

Length 2090 MM

Width 750 MM

Height 1095 MM

Wheelbase 1340 MM

Fuel tank capacity 13 Ltr

Reserve 13 Ltr

PERFORMJANCE

Accelerato (0-60 KM) 5 sec

Mileage 60 KMPL BODY

Frame Advanced design demand Frame

Front suspension telescoic frock

Rear suspension Advanced technology more suspension

Front tire 2.75-18

Front break tier 240 MM disk

Rear break type 130 MM Drum

ENGINE AND

Engine Type 4-Stroke air-cooled OHC single cylinder

Displacement 149.1cc

Net Power 13.3 bhp@8000 rph (9.9 K.m0

Torque 1.3 ch.qm @ 5500 rph (12.8 K.m)

Air filter Paper type

Corroborator cv type

Transmission Constant Mesh, 5 Speed gare

Gear Shift Patter 1 down 44P

Electrical

Ignitions Digital CDI (multi Mapping)

Stating Kick/self

Battery 12.2.5 Ah ()Kick) /12-7 Ah (Self)

Head lamp Haloquen 12v/35 w

PARTS OF A MOTORCYCLE

Parts of Motorcycle

This diagram illustrates some of the important parts of a typical motorcycle. Transmission controls, such as the and gearshift levers, are located on the handlebars or foot rests, where the rider can easily operate them. The rear shock absorber and other components of the suspension system cushion the rider from bumps and jolts of the road. The exhaust pipe carries exhaust generated by the engine to the rear of the motorcycle.

In their simplest form, motorcycles consist of a gasoline engine attached to a two-wheeled steel or aluminum frame. A fuel tank sits above the engine and usually sports the name or logo of the motorcycle’s manufacturer. The front wheel and axle is attached to the frame with a fork, a two-pronged, pivoting arm. Turning the handlebars at the top of the fork causes the wheel to pivot. Power from the engine turns the rear wheel. The rear axle is connected to the frame with a shock-absorbing arm.

A Engine

A .

The engine of a motorcycle is suspended within the vehicle frame between the front and rear wheels. Like internal combustion engines that power automobiles, motorcycle engines transform chemical energy into mechanical energy by igniting a volatile mixture of fuel and air within a cylinder, causing gases to expand suddenly. The expanding gases push down on a piston, which turns a crankshaft. The crankshaft transforms the energy from the piston into rotary motion. The rotational force of the engine’s crankshaft turns other shafts and gears that eventually cause the rear wheel to rotate.

Engines with larger cylinders—or more of them—are more powerful and consume greater amounts of fuel. An engine’s displacement, or size, is expressed in terms of the number of cylinders it has and the total volume, in cubic centimeters (cc), displaced by each cylinder. Motorcycles may have single-cylinder, twin-cylinder, four-cylinder or even six-cylinder engines with displacements that range from 250 cc to 1500 cc or higher.

The cylinders in two- and four-cylinder engines may be arranged parallel to one another. Engines with this cylinder configuration, called inline engines, are usually mounted sideways in the . In other engines, cylinders are canted at a 45-degree angle, in what has come to be known as a V-configuration. In two-, four-, or six-cylinder engines, cylinders may also be positioned horizontally opposite one another. The horizontal configuration produces less vibration than V- configurations or inline configurations do. It also lowers the center of gravity of the engine, improving motorcycle handling.

Motorcycle engines are also distinguished by the number of movements, or strokes, a piston makes per cycle. In four-stroke engines, the piston moves four strokes, igniting on the third stroke and expelling the spent gases on the fourth. Two-stroke engines have a simpler design that enables them to fire in two strokes. However, two- stroke engines burn a combination of oil and fuel, thus producing more pollutants than four-stroke engines, which separate the oil and the fuel. Some motorcycles have single cylinder two-stroke engines, but all motorcycle engines that have multiple cylinders are four-stroke to reduce exhaust emissions.

B Ignition and Fuel Delivery System

An engine’s ignition system controls the spark that ignites the fuel in a cylinder. Smaller displacement engines for off-road use typically have a kick-starter, a starter crank activated with the rider’s foot. Larger displacement engines and those designed for street use have an electric starter activated by turning a key in the ignition and pressing a starter switch.

Riders regulate motorcycle speed with a twist-grip on the right handlebar called the throttle. Twisting the grip backwards opens a throttle valve in the engine, increasing the amount of air and fuel that enters the cylinders. In older motorcycle engines, twisting the throttle increases the amount of fuel and air pulled into the carburetor, a device that mixes the fuel and air before it is delivered to the cylinders for combustion. Many motorcycles built after 1990 have fuel injection systems instead of carburetors. A fuel injection system uses computer- controlled fuel injectors to spray measured amounts of fuel into each of the engine’s cylinders.

C Transmission

A motorcycle transmission and system.

Most motorcycles have a manual, five-speed transmission. The transmission consists of a series of gears, shafts, and other parts that control the forward motion of the motorcycle and enable it to maintain high cruising speeds. To change gears, the rider activates a clutch lever on the left handgrip to disengage engine power from the transmission, and then shifts a foot-operated gear lever on the left side of the motorcycle. Some motorcycles have automatic transmissions, which eliminate the need for a clutch and manually shifted gears.

On most motorcycles, the transmission delivers engine power to the rear wheel via a drive chain. Chains stretch with age and require periodic adjustment. In some motorcycles, a cogged rubber drive belt or an enclosed replaces the drive chain. Belts and drive shafts do not require adjustments and operate more quietly than chains.

D Brakes

The front and rear wheels on a motorcycle each have a brake. Most motorcycles have a disc brake in the front and a disc or in the rear. The rider activates the front brake with a hand lever on the right hand grip. The rear brake is operated with a foot pedal on the right side of the motorcycle.

E Frame and Suspension System

Motorcycles have a steel or aluminum tube or box frame. Some have full frames that encompass the engine, while others have partial frames to which the engine is attached. Motorcycles with partial frames tend to be lighter in weight than those with full frames.

The frame also supports the suspension system, a collection of springs and shock absorbers that helps to keep the wheels in contact with the road and cushions the rider from bumps and jolts. The front wheel and axle are mounted on a telescoping fork with internal shock absorbers and internal or external springs. The suspension on the rear wheel and axle consists of either a pair of shock absorbers or a single shock located within the frame.

F Seats and Accessories

The seats on most motorcycles are located behind the gas tank and are designed to carry one or two passengers. Some seats have small cargo compartments underneath or behind them to carry small items. Add-on hard plastic boxes or leather pouches called saddlebags may be installed on either side of the rear wheel or over the rear fender to increase cargo carrying capacity. Large motorcycles may also be fitted with a trailer hitch to pull a small trailer. A is an add-on accessory that can be installed to carry an extra passenger. The sidecar has its own wheel for added support and may have an enclosed seating compartment for all-weather riding.

2.1.2 Basic Manufacturing Process

Raw Materials

The primary raw materials used in the manufacture of the body of motorcycle are metal, plastic and rubber. The motorcycle frame is composed almost completely of metal, as are the wheels. The frame may be overlaid with plastic. The tires are composed of rubber. The seat is made from a synthetic substance, such as polyurethane. The power system consists of a four-stroke engine, a carburetor to transform incoming fuel into vapor, a choke to control the air-fuel ratio, transmission, and drum brakes. The transmission system contains a clutch, consisting of steel ball flyweights and metal plates, a crankshaft, gears, pulleys, rubber belts or metal chains, and a sprocket.

The electrical system contains a battery, ignition wires and coils, diodes, spark plugs, head-lamps and taillights, turn signals and a horn.

A cylindrical piston, made of aluminum alloy (preferred because it is lightweight and conducts heat well), is an essential component of the engine. It is fitted with piston rings made of cast iron. The crankshaft and crankcase are made of aluminum. The engine also contains a cylinder barrel, typically made of cast iron or light alloy.

The Manufacturing Process

1. Raw materials as well as parts and components arrive at the manufacturing plant by truck or rail, typically on a daily basis. As part of the just-in-time delivery system on which many plants are scheduled, the materials and parts are delivered at the place where they are used or installed. 2. Manufacturing begins in the weld department with computer-controlled fabrication of the frame from high strength frame materials. Components are formed out of tubular metal and/or hollow metal shells fashioned from sheet metal. The various sections are welded together. This process involves manual, automatic, and robotic equipment. 3. In the plastics department, small plastic resin pellets are melted and injected into molds under high pressure to form various plastic body trim parts. This process is known as injection molding. 4. Plastic and metal parts and components are painted in booths in the paint department using a process known as powder-coating (this is the same process by which automobiles are painted). A powder-coating apparatus works like a large spray-painter, dispersing paint through a pressurized system evenly across the metal frame. 5. Painted parts are sent via overhead conveyors or tow motor (similar to a ski lift tow rope) to the assembly department where they are installed on the frame of the motorcycle 6. The engine is mounted in the painted frame, and various other components are fitted as the motorcycle is sent down the assembly line 7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, lights, radios, and hundreds of other parts are installed on the motorcycle frame. A motorcycle, for example, needs almost as many parts to complete it as a Honda Civic automobile.

INTRODUCTION TO GOCHI  Methods Involed  Design  MUANUFACTURING THE FRAME OF BIKE FACING AND TURNING ROUGH TURNING FINISH TURNING DRILLING HOBBING ROLLING WELDING GRINDING HARDENING AND TEMPERING INSPECTION

CONCLUSION

Summer training in Escorts Ltd. really helped me to familiarize myself to the practical knowledge of industrial production and processes. The whole training period was very interesting, instructive and challenging. Through this training I was able to gain new insights and more comprehensive understanding about the real industry working condition and practice. I got the idea of working of automatic CNC machines, Testing techniques of Diesel engine, tractors and different processes used in machining of cylinder block and Assembly plant. All of this valuable experience and knowledge that I have gained were not only acquired through the direct involvement in task given but also through other aspect of the training such as work observation, interaction with operators, supervisor and other peoples involved in the process. In assembly plant i saw how tractor are assembled. I get knowledge about differentdifferent sub assemblies of tractor assembly plant. Differential sub assembly, transmission sub assembly, transmission testing, paint of body and different sub stations. It was a good idea and good chance to expose to the work environment that we will have to face and practice after we graduate. As a result of the training now I am more confident to enter the employment world and build my future career.

Bibliography  www.google.com  www.wikipedia.com  www.escortagri.com  WWW.SCRIBD.COM  WWW.SLIDESHARE.NET  Text Books  Company Production Documents