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 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 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 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. Escorts Group Type Public Limited Industry Engineering Conglomerate Founded 1960 Founder(s) Hari Nanda and Yuri Nanda Headquarters Faridabad, India Area served Worldwide Key people Rajan Nanda (Chairman and Managing Director) and Nikhil Nanda (Joint Managing Director) Tractors, crop solutions, cranes, loaders, shock Products absorbers, struts, steering components, brakes for railways, couplers Employees 6,000 (2011) Website www.escortsgroup.com Tragically. . Then Escorts Agents Ltd .. Was merged in 1953 to create a single entity Escorts Agents Pvt. 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. Ltd. And Escorts (Agricultural Machines) Ltd. was effected on 18th January 1960. After that owning to the opportunities lying in the Indian villages Escorts (Agricultural Machines) Ltd. 1944 with YUDI NANDA as managing director and HARI NANDA as the chairman. Escorts Ltd. Escorts agents limited was born at Lahore on 17th Oct. It has pioneered farm mechanization in India through import and distribution of agricultural tractors.Historical Background Escorts came into being with a vision and a mission. was launched in 1948 with YUDI NANDA as the director. he died in an accident in 1952. Escorts has come a long way in manufacturing and marketing a large range of products. The company’s incorporation in its present name. Having initially started with a franchise for vesting house domestic appliances. Escorts had inducted the latest technology by forming alliances with the world’s most advanced Engineering and Electronic companies. which grew from a small beginning to one of the ever-changing dimensions. constantly adopting their technology according to India’s need and situation.At every step of the way. For five decades Escorts has been in the core sectors like Agriculture. adjusting to ever changing markets. The source of Escorts consistent growth is commitment and contribution to the core needs of the country. Construction & Resources for Engineering change through optimum product performance. Transportation. 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. As early as in 1944 while . Escorts have firmly believed that success depends on being close to the customers. The single word completely described the character philosophy and success of the company. 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. 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 manufacturing operations commenced in 1954. 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. comes into being. soon to make the group the largest selling tractor manufacturing .. substantial man-hours are being devoted to planning a new range with the objective of consistently offering greater value to the customer. Escorts has induced the latest technology to make products that are not merely “better” but those meet international standard.others were concentrating on selling their goods . in equity collaboration with Goetze of Germany. Anil Nanda as a ViceChairman the ideals have not changed. Goetze (India) Ltd. Rajan Nanda as a Chairman and Mr. the distinct. with a tractor franchise.In Lahore and setting it all up again in Delhi after the country’s partition . A full-fledged manufacturing orientation takes roots with the commencement of Escorts’ own brand of tractors and next major field of operation: motorcycles.The beginning of an industry legend.. In every step. undisputed edge of technology and the internationalization of business.Escorts sought to “Escorts” its merchandise right up to the customer’s doorstep. every corporate endeavor addresses to the end users and the ever-changing market. a unique venture in industrial democracy. For Escorts. 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 . The company joins hands with Mahle to produce India’s most advanced pistons. these are two benchmarks of industrial achievements. followed by India’s first institute of farm mechanization and the company’s first industrial venture. giving them a product that met these needs ensuring that it worked smoothly thereafter. THE DECADE OF CONSOLIDATION: 1965-1974 The foundation of the Ford-Escorts alliance for India’s finest tractors. This meant staying close to the customer. THE DECADE OF AUTOMATION: 1955-1964 Escorts goes public.Escorts Employees Ancillaries Ltd. “In every area we touch our task has always remained one of engineering change” Rajan Nanda. . Thus. understanding their needs. at Patiala. Today with Mr. Escorts is going in for a global network and for mega projects in the 21st century. Acknowledged leadership in automotive ancillariesMahle pistons and Goetze rings . alliances with JS telecom. With the Yamaha collaboration. world leaders in VSAT networks. the ultimate victory providing the unshakable confidence of the company’s small shareholders countrywide. and Hughes Network systems. THE DECADE AHEAD: 1996 The Mission is Globalization and the emphasis will be on core sector investments. A tie-up with Faun. this was perhaps the world’s largest ever commercial airlift of its kind. Escorts become the country’s largest motorcycle manufacturer. 15 billion. Escorts turnover crosses Rs. . In the sunrise telecom sector. hailed as among Asia’s most advanced. Escorts Heart Institute commissioned. Escorts fights an epic battle against a corporate raid. powers the company to supremacy in hydraulic mobile cranes. 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. won in a global tender.Escorts receives FICCI Award for outstanding contribution to Indian agriculture . A triumph of Escorts quality and competitiveness. 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.The company crossed national boundaries with its first export of 400 tractors to Afghanistan. a Bosch company. ESCORTS: RESTRUCTURING Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its inherent strengths. In order to meet the challenge of the future and to leave an indelible mark on industrial scenario. combining them with India’s intrinsic cost advantages to become a global source point for high value engineering products. a strong presence in the Core Sector providing complementary product lines and a vast marketing network. a strong presence in the Core Sector providing complementary product lines and a vast marketing network. Escorts Limited is all set to meet the future by drawing on its 50-year equity gained from its inherent strengths. combining them with India’s intrinsic cost advantages to become a global source point for high value engineering products. 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 . in the words of Mr. Chairman Escorts Limited. EDDAL Escorts Dealer Development Association providing management and financial support to dealers . It has been a prime mover on the industrial front. . we are once again adapting ourselves towards being catalysts for qualitative growth by Engineering Change with a global perspective. Rajan Nanda.ESCORTS – THE GROUP INFRASTRUCTURE The flagship of the Escorts group is Escorts Ltd.. Today as the nation engages in its most momentous economic transformation ever.” 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. “in the last 50 years Escorts has been more than merely one of India’s largest Engineering Companies. at every stage introducing products and technologies that helped take the country forward in key areas. GOETZE (India) Ltd. exvators.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. o Escorts Mahle Ltd. o Carraro (India) ltd. . o IFS India Escorts o Hughes Escorts communication ltd. truck loaders) o Esconet services o Escorts Automotives(Investment) o Escosoft technologies o Escortal tele communication ltd. o Escorts Employees Ancillaries Ltd. (cranes. o Escorts securities ltd. o GOETZE (India) assets management Ltd. o Escorts Finance Ltd. o GOETZE TP (India) 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. Piston Rings Aluminum Cylinders Shock Absorbers Carburetors Magnetos Clutches Air Brakes Couplers Electro-Pneumatic Brakes Shock Absorbers Cellular Telephone services VSAT Services (satellite communication system) Automobile Financing Consumer Finance Mutual Funds Fixed Deposits Machining Painting Assembly Engine PU Transmission PU Rear Axle PU Assembly/tractor PU Personnel & HRD Finance Manufacturing Engineering Plant Engineering & Machine Maintenance Information Systems Automotives Railways Telecom Financial Services Manufacturing Facilities Product Units(Pus) Departments .ESCORTS GROUP CORE BUSINESSES BUSINESS GROUPS PRODUCTS Agri-Machnary Tractors Construction equipment Earth moving Machines Vibratory Rollers Material Handling Equipments Pistons. CNC. Gear Cutting. The plant is equipped with the following facilities:MACHINE SHOP : EPU. 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 . The different components machine in these shops with their respective sections are listed below: o Cylinder Head. o Case Transmission. o Turning. In heat treatment shop following facilities are available: o Gas Carbonizing. o Center Housing & Trumpet Housing. RAPU AND TPU have separate machine shops equipped with several purpose machine (SPM) as well as Computerized Numerically Controlled (CNC machine).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. Grinding & Heat Treatment. o Tool Room. Cylinder Block and Connecting Rod. I had discussed various project ideas.PROPOSED IDEAS Before coming to the select final project that is “STUDY AND UPDATION OF PROCESS OF CLYNDER BLOCK E 3-312”. iii) It is needed because some Machine are Replace By new Machine and sequence is also alter. 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. 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. 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. 1. . 2. Time Study of process. i) It covers Both “Time Study of Process” and “Inspection and Instrument”. ii) Scope of Knowledge is more. Inspection sector 3. Reasons for Rejection: i) Source Of Knowledge Is small. HEAD FACE: Rough and semi finish milling operation 2. SUMP FACE: Rough and semi finish milling operation CUTTING TOOL DETAIL Face milling cutter Sump side Diameter 500mm Insert span 1203 THN/H13A Head Side Diameter 400mm Insert span 1203 THN/H13A .ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B DUPLEX MILLING MACHINE (SPM) BSM-8 20 7mint OPERATION DESCRIPTION Rough and finish milling operation on sump face and head face is occur on this machine. 1. fed past the same In doing so.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). DUPLEX MILLING MACHINE (SPM) PROCESS: This is a special purpose machine (milling). the teeth of the cutter remove the metal . Milling Operation occurs on head face and sump face. In this machine only face milling operation occur. Reference of work piece also known as dowel . clamped on the machine table. The whole process is occurs in reference of DOWEL as shown in the diagram. in the form of chips from the surface of the work to produce the desire shape. where is the cutter of diameter in [mm] according to: Ns = 1000 V/ p D . As before. The surface is parallel with the axis of rotation of the cutter.BRIEF DISCUSSION OF MILLING OPERATION Milling is a basic machining process by which a surface is generated by progressive chip removal. Process Explanation: Milling operations can be classified into two broad categories called peripheral milling and face milling. these variables depend upon the work material. The rpm of D the spindle is determined from the surface cutting speed. the cross section of the resulting surface corresponding to slab milling. the axial contour of the cutter. In nearly all cases. This process. often called is usually performed on horizontal spindle milling machines. The work-piece is fed into a rotating cutting tool. the tool material. the cutting speed and feed per tooth are selected by the engineer or the machine tool operator. The cutting velocity is that which occurs at the cutting edges of the teeth in the milling centre. because very good surface finish can be obtained. Each has many variations. more flat surfaces are produced by milling than by any other machining process. Unquestionably. In slab milling. a multiple-tooth cutter is used so that the material removal rate is high. which depends on the feed per tooth. V As in the other processes. Often the desired surface is obtained in a single pass of the cutter or work and. milling is particularly well suited and widely used for mass-production work. Sometimes the work-piece remains stationary. Both flat and formed surfaces can be produced by this method. the tool rotates at (Ns) fm some rpm while the work feeds past the tool at a table feed rate in mm per ft. and the cutter is fed to the work. Many types of milling machines are used. and the specific process. 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. minute. In the surface is generated by teeth located on the periphery of the cutter body. In up milling. Because the relative motion tends to pull the work piece into the cutter. 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. the smoothness of the generated surface depends greatly on the sharpness of the cutting edges. therefore. the cutter rotation is in the same direction as the feed rate. then it increases in thickness. The cutter tends to push the work along and lift it upward from the table. In down milling. chips can be carried into the newly machined surface. any possibility of looseness in the table feed screw must be eliminated if down milling is to be used. In addition. maximum chip thickness occurs close to the point at which the tooth contacts the work. the action also tends to loosen the work from the clamping device. It should never be attempted on machines that are not designed for this type of milling. Up milling is the traditional way to mill and is called conventional milling. surfaces can be generated by two distinctly different methods. In up milling. In climb or Down milling.UP VERSUS DOWN MILLING For either slab end or face milling. However. . causing the surface finish to be poorer (rougher) than in down milling. the chip is very thin at the beginning where the tooth first contacts the work. The cutter rotates against the direction of feed of the work-piece. becoming a maximum where the tooth leaves the work. greater clamping forces must be employed with the danger of deflecting the part. The method of chip formation is completely different in the two cases. Another advantage of down milling is that the cutting force tends to hold the work against the machine table. This may cause the teeth to dull rapidly. . permitting lower clamping forces. used in a milling machine to remove material from the work-piece through the relative motion of work-piece and cutter . Metals that readily work harden should be climb milled. However.Virtually all modern milling machines are capable of doing down milling and it is a most favorable application for carbide cutting edges. MILLING TOOLS AND CUTTERS A rotary tool-steel cutting tool with peripheral teeth. as castings sometimes do. 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. Because the material yields in approximately a tangential direction at the end of the tooth engagement. and the cutting process is smoother with less chatter. there is less tendency (than when up milling is used) for the machined surface to show tooth marks. Basic Operation: . CAP SEAT Rough / finish milling operation CUTTING TOOL DETAILS 1.7mm 5 Reaming Tool of Dia.2 3.HSS T. 13H7 . 13H7 of 2 dowel Drill Dia. 12.S. SUMP FACE Finish milling Drilling – Hole milling-Reaming of dia.10.T.T-Max Face milling cutter Radius 265. Milling Cutter 3.S. HEAD FACE Finish milling operation 2.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B HTC-630 & HTC 600 (SPM) BMC-8 & BMC-16 30 PERATION DESCRIPTION 1. Hole Mill Tool of Dia.C.4-125-10 2.5 Drill two holes on L-pad of Dia. Drill Tool of dia.S. 12mm 4. 18. Drilling is a major and common hole making process other processes for producing holes are punching and various advanced machining processes. 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. 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. often multipoint. They commonly used drills can be classified in many ways. According to the type of shank they carry: a) Parallel shank b) Taper shank 2. 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. as follows: 1. Because drills usually have a high length-to-diameter ratio the next figure they are capable of producing relatively deep holes. According to the type of Flutes : a) Flat or Spade drills (parallel longitudinal flutes) b) Twist Drills (spiral/ helical flutes) 3. The drill bit is a rotary cutting tool. Classification of Drill: Drills are manufactured in several different forms and sizes. cutting off chips from what will become the hole being drilled. This forces the cutting edge against the work piece. Hole making is among the most important operations m manufacturing. The bit is pressed against the work piece and rotated at rates from hundreds to thousands of revolutions per minute.BRIEF DISCUSSION OF DRILLING OPERATION Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. . In automotive engine production the cost of hole making is one of the largest machining costs. 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. . Consequently chip disposal and the effectiveness of cutting fluids can present significant difficulties in drilling.Also drilled holes may be subjected to subsequent operations for better surface finish and dimensional accuracy such as reaming and honing. TWIST DRILL The most common drill is the conventional standard-point twist drill Fig.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. The amount of oversize depends on the quality of the drill and of the equipment used as well as on the practices employed. Drills generally leave a burr on the bottom surface upon breakthrough necessitating de-burring operations. (a) the main features of which are the point angle lip-relief angle chisel-edge angle and helix angle. 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 . 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. A spot drill is used to spot to start a hole at the desired location on a surface. A step drill produces holes of two or more different diameters. 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. Some drills have internal longitudinal holes through which cutting fluids are forced improving lubrication and cooling as well as washing away the chips. . Spade drills have removable tips or bits and are used to produce large and deep holes. 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. The grooves also serve as passageways to enable the cutting fluid to reach the cutting edges. A core drill is used to make an existing hole larger. Crankshaft drills have good centering ability and because chips tend to break up easily these drills are suitable for producing deep holes. Several types of drills are shown in the next figure. This feature is important in drilling with automated machinery where disposal of long chips without operator assistance is necessary. Counter-boring and countersinking drills produce depressions on the surface to accommodate the heads of screws and bolts.Generally two spiral grooves flutes run the length of the drill and the chips produced are guided upward through these grooves. Other Types of Drills. Drills are available with a chip-breaker feature ground along the cutting edges. Narrow raised section of the body.Twist Drills Twist drill is the most widely used in the modern drilling practice. BODY a) Flutes . It consist of a cylindrical body carrying two spiral flutes cut on it. Forms the chisel edge of the drill. SHANK This is the portion which is “clamped” to provide the drive. a) Lips b) Cutting edges . shank can be tapered or reduced. POINT . 2. Straight shank for drill up to ½” . Parts of Twist Drill Three main components are the: Shank Body Point 1. This feature increases as it extends to the shank. Provides full body to hole support to help keep it aligned as it drills.Chisel edge of the drill. Above ½”.Thin section in the center of the drill which forms a “core” for the drill.Reduced section of the drill between the flutes and margin. c) Body clearance .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. Used to reduce friction between drill and workpiece d) Web. 3. Shank is equal to body diameter. Tin coated drills. parabolic drills. .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. split point drill. carbide coated masonry drills. S. NAME PLATE SIDE Rough/ Finish Milling Drill/TAP of M-14 2. . 36H8.36H8 (3 holes) 3.S T. TIME GEAR SIDE (TGC) Mill Water impeller seat Drill of Dia. STD H. 40mm & 50mm 3. STD Facing Milling Cutter R 265.4 2. Drill of dia. Finishing Bore Bar of dia.S. 5.5*8 4. 36H8. TAPPET COVER SIDE (TCP) Rough/Finish Mill Rough/Finish Bore of Dia.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B HTC-600 & Yasda (SPM) BMC-11 40 PERATION DESCRIPTION 1. End Milling Tool of dia. Ø 5 CUTTING TOOL DETAILS 1. Finishing Bore Bar of dia. ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B CNC DUPLEX MILLING (BM-211) BSM-11 50 6 Minute PERATION DESCRIPTION TIME GEAR SIDE a)Rough/finish mill BELL HOUSING SIDE a) Rough/finish mill CUTTING TOOL DETAILS 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 . ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B WEB & NTCH MILL (BM-147) BSM-6 60 6 Minute PERATION DESCRIPTION Plunge mill web thickness & 4 notches on cap seat CUTTING TOOL DETAILS 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 RHhmt No.hmt No. ( ) TEF half side face milling cutter L. BM-147-9401-39 .H. S.8 x 195FL x 250OAL (M35) tin coated MT-1 H. TS Drill Ø 9 x 195FL x 295OAL (M35) Tin coated MT-1 .S. Drill from Crank to Idler Bore of Ø 6. Drill Ø 6.S. TS drill Ø 7 x 300FL x 350OAL (M35) Tin coated MT-1 H.8–1 hole.S. 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 CUTTING TOOL DETAILS H. Drill Ø 15x 350FL x 450 OAL (M35)TIN coated MT-2 H.4 holes. T.S.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B OIL GALLERY SPM(M348) BSD-13 70 7:00 MINT PERATION DESCRIPTION Drill oil gallery hole from Crank to Cam bore of Ø9 x Ø 7.S.S.S.S. Drill of Ø14-1 hole. Ø12.5 PERATION DESCRIPTION CUTTING TOOL DETAILS BELL HOUSING SIDE Drill Oil Gallery Of Ø 14 TAPPET COVER SIDE Drill/Tap M10-6 hole.8/25. Ø12. NAME PLATE SIDE Drill of Ø 12.5 hole . M12-3hole. 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 Ø10.5 .ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B SNCH-11 & HMC-5008 BMC-7 & BMC-9 120 28. 5 MT-2 STD Drill Ø5 .5-2 holes Drill Ø 12-14 holes Drill Ø 14.5-14 holes Drill Ø5-4 holes CUTTING TOOL DETAILS STD T.5-233OAL ALT Drill STD Core Drill Ø14.5 x 212OAl (Tin coated with M35 material) STD Core Drill Ø 18.10 MINT PERATION DESCRIPTION HEAD FACE Drill Ø 12-14 holes Drill Ø14.S.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B HEAD FACE DRILL(E-363) BSD-14 ALT:.5-2holes Drill Ø18.RADIAL DRILL 90 4. Twist Drill Ø12h8 x 225 OAL (Tin coated with M35 HSS material ) STD Core Drill Ø14. Ø14 x 108FL x 189 OAL Dia. Twist Drill Dia. Twist Drill Ø7 x 156OAL .S.2 x 116FL x 197OAL Dia. Ø 10.23 PERATION DESCRIPTION TIME GEAR SIDE Drill Ø6.5-2 dowel BELL HOUSING SIDE Drill Ø10.8 x 156OAL TET-6367 H. Twist Drill Ø6. T.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B 2 WAY MULTIDRILL SPM (Y-1643) BSD11 100 2.S Twist Drill (MT-1) Dia.S.S.S. S. Ø12 x 101FL x 182 OAL TET-2272 H.S.S. S.S. Ø9 x 107FL x 188OAl STD H.S.2-10 holes Drill Ø12-2 holes CUTTING TOOL DETAILS STD H.S.8-17 holes Drill Ø14-4 holes Drill Ø7-1 holes Drill Ø8.S. 5-8 holes HEAD FACE Tap M14-12 Holes CUTTING TOOL DETAILS STD H.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B MULTIDRILL SPM (MD-419) BSD-10 110 5:00 MINT PERATION DESCRIPTION SUMP FACE Drill of Ø 8.S.S.S.S. TS Drill Ø16.5 x 181 OAL MT-1 STD H. TS Twist Drill Ø14 x 223 OAL MT-2 STD H.10 holes CAP SEAT FACE Drill Ø 14 & Counter Drill Ø16.S.S.5.6 x 223 OAL MT-2 . TS Twist Drill Ø 16.S.S. TS Twist Drill Ø6.5 x 223 OAL MT-2 Alternate STD H. 5 Type C M16 x 2 Type C M20 x 1.5 Type C M12 x 17.5-1 hole BELL HOUSING SIDE Tap M12-10 holes CUTTING TOOL DETAILS STD Machine Tap M10 x 1.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B TAPPING MACHINE(RADIAL DRILL) BTM-1 130 14:00 MINTS PERATION DESCRIPTION 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.25 Type C M14 x 2 Type C .5 Type C M8 x 1. Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Air Cleaning & Cap Fitting PERATION DESCRIPTION CUTTING TOOL DETAILS Simple Machine working ESCORTS LIMITED COMPONENT PLANT CASTING AREA . CUTTING TOOL DETAILS TFE-6091 Boring Bar for Crank Bore.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.Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Rough Boring SPM BSB-6 140 10.16 STD T max Insert TPUN160308-H-20 TEF-6095 Boring Bar for LAN Bore .9 – 1320. 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.75 PERATION DESCRIPTION ROUGH BORE OF a) Crank bore b) Cam bore c) Idler bore. 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 .ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Lime Boring SPM(YB017& Y3304) BSB-5 150 4-9 Min PERATION DESCRIPTION FINISHED / SEMI FINISHED BORE OF a) Crank Bore b) Cam Bore c) Idler Bore CUTTING TOOL DETAILS TET-9180 Boring Bar for Crank Bore TET-3244 Boring Tool STD T-Max Catridge R-437.9-1214. ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Lime Boring SPM(Y3304) BSB-8 180 4.46 Min PERATION DESCRIPTION BORE OF a) Sank Bore b) Cam Bore c) Idler Bore CUTTING TOOL DETAILS 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 . S. 10H7 TEF-6449 Boring Bar For Dia.G. Insert STD CCMT 060204 THM TEF-6524 Locating PIN for T.S. 10H7-2 Dowel Holes.S. Hole mill/Ream Dia. TIME GEAR SIDE Bore Dia.H. 10H7 TEF-6523 Locating PIN for B. CUTTING TOOL DETAILS TEF-6529 Tool Holder For Dia-13H7 TEF-6500 Boring Bar For Dia-13H7 TEF-6542 Tool Holder For Dia.C.35 Min PERATION DESCRIPTION BELL HOUSING SIDE Bore Dia. 13h7-2 Dowel Holes.ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Dowel Hole SPM FB-668 (BS7-9) 200 3. Ø -10h7-2 Dowel Holes. 13H7 155445 .S Reamer Dia-10H7 15. ALTERNATE On Radial Drill STD Collect MT-1 For Q.S H Mill Dia. Ø -13h7-2 Dowel Holes.S. 12.7H9 STD H.C STD H.5445 TET-2053 H.S Reamer Dia. Hole Mill/Ream Dia.S. 5 TET-6620 End Mill 36 x 65FL x 157OAL MT-3 TET-6672 JIG Bar For Hole Mill .ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B Tappet-SPM (Y-3505) BSD-16 190 8:00 Min PERATION DESCRIPTION End Mill Drill Hole Mill Ream – 24H8-6 Tappet Hole CUTTING TOOL DETAILS TET-6671 JIG Bar For Drill 22. ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B VTC-3 & VTC-5 PERATION DESCRIPTION Drill Oil dip stick hole.18H8-2. . CUTTING TOOL DETAILS STD Tap Driver for M8(MT-2) STD Machine Tap M8 x 1.25 Type 'C'. Drill/Tap M8-2 holes Time Gear Side. thru Hole Mill/Ream dia. 10-3 Holes. CUTTING TOOL DETAILS .ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B VCRT MACHINE G CENTER(LMV55) PERATION DESCRIPTION Finish milling head face.20H8-2 Dowel Holes. Hole Mill/Ream Dia. Finish Bore linear Bore. Drill Dia. ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B INSPECTION AND CLEANING PERATION DESCRIPTION INSPECTION PLACE CLEANING MACHINE CUTTING TOOL DETAILS . ESCORTS LIMITED COMPONENT PLANT CASTING AREA Part Name Part Number Machine Name Machine Number Operation Number Cycle time D10025590B MANUAL BUSH PRESSING MACHINE PERATION DESCRIPTION Fit 4 Cam Bush . Bush CUTTING TOOL DETAILS . 02) Flush pin Gauge width Dial TEG-6265 12. Cam Bore Dia. Idler Bore Depth Of Thrust Face position of linear bore Gauging fixture TEG-6046 13. Position of Crank. Thrust Bearing Dia. STD 10. Thrust Face Thickness 42(-. Tappet Bore Dia. DISCRIPTION DIMENTION INSTRUMENT GAUGE 1. Cam. Dia. 32H7 D. 3-Holes on Tappet Cover side 36H8 Dial Bore Gauge STD 3. Idler Bore Dia. 56H7 Dial Bore Gauge STD 4.OPERATION FINAL INSPECTION S.B.12 Plate Gauge TEG-3249 5. 110+0.G. Linear Bore Stud Hole Clearance Functional Gauge TEG-6393 .055/91. 24H7 Dial Bore Gauge STD 2.009) Width Gauge TEG-2250 6. Alignment of crank Bore 0.02 Mandrel TEG-6244 7. of Linear Bore 120H7 121H7 130H7 Dial Bore Gauge STD 11. 91. Alignment of Cam Bore 0. Crank Bore Dia. Depth of C'Bore From Head Face 11(+0.02 Mandrel TEG-6202 9.NO.02or-.085 Dial Bore Gauge STD 8. Check all liner bore for fouling of linear will wall. All oil galleries to be cleaned and blown through by air under pressure. Check all Threaded holes for threading depth. Water impeller seat to be checked for fouling of impeller with side walls. .TECHNICAL CONDITIONS All oil galleries to be checked with dia.3mm wire for through holes. Bore . Crank. .ISHIKAWA CHART Diagnose the cause of failure of Cam. team leaders and employ of the company. It also help me to get knowledge about the tools and there different-different properties and types. 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. 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. The aim STUDY AND UPDATION OF PROCESS is to get knowledge of all process occurs in this cylinder block.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. Some new things which i learned from this company are Use of different –different gauges. . THANKYOU .