ACKNOWLEDGEMENT

I would like to show my gratitude towards every person, who helped me in any way to complete my summer training. I am very thankful to Mr.V.K. Grover(A.G.M. Training centre), who had given me such a golden opportunity to join me four weeks training at an esteemed organization INDOFARM from which I learned a lot about practical working, which I had studied in theory only.

Secondly, I would like to thank instructors and every operator, who gave me complete support to gain knowledge about the machinery and operations done on them.

Lastly, I would thank my parents and college authorities for their immense support. The whole success of this training should be credited to them and failure, if any, should be credited in my favour.

PREFACE
With specialization in the plant, Tractor Division deals with various aspects of Mechanical Engineering and especially about manufacturing of its different parts. In our curriculum of four weeks training period included in fifth semester of fouryear degree course, I have completed my training session (1st July to 31th July). I worked in various sections of company and gathered observations. This report describes about all the departments, which were under my observations.

INTRODUCTION
INDOFARM INDUSTRIES LIMITED.is a dream come true. The
company started with a single objective.to manufactures a tractor that every farmer can afford. This led us to explore the world markets and ultimately we came across one of the most reputed names in the world for tractor engines- Ursus

Diesel Company Ltd., Poland. Consequently we were able to provide a quality tractor to farmers. Encouraged by the overwhelming response from tractor industry,
INDOFARM have diversified into infrastructure equipments with the first product, hydraulic pick N carry crane to cater to the needs of industrial, construction and mining sectors . Engines being our core competence area, We are now making engines for generator sets to address the overgrowing global demand for electricity.

BRIEF OVERVIEW OF BADDI PLANT;

Commenced manufacturing operations in technical collaboration with Ursus (Poland) in 2000 at its plant located at Baddi in Distt. Solan of Himachal Pradesh. Plant spread over an area of 34 acres. Installed capacity of 12000 tractors. State-of-art Machine Shop having more than 1500 modern machines, SPMs and latest CNC machining centres for producing excellent quality components like Cylinder heads, Blocks, Transmission Housings, Gear boxes, Hydraulic housings, Axle tubes, Cages, Timing cases &covers, Sump, Flywheel housings, etc. Manufacturing range of tractors in the Horse Power range of 30 HP to 65 HP. Separate Research, Design and Development cell, industrial in developing tractors using latest technology for catering to over-changing frming needs. Company has its own Foundry unit commissioned in 2006. Ensures better product quality. Top management comprises of professionals with rich industry experience.

ABOUT INDOFARM TRACTORS:

INDOFARM, one of leading public sectors Company in India has been contributing towards the ushering in of the green revolution in India with its proven machinery besides building a strong industry base for economic development of country. Through constant endeavor INDOFARM has brought in expertise and excellence, a high caliber of know-how quality control to its agricultural machinery range. To give farmer best in world, INDOFARM entered into collaboration with one of choicest names in agricultural machinery business. The expertise thus gained has enable INDOFARM to introduce over the years, tractors of all kinds of souls and different farming conditions. Today, INDOFARM has over two lacs in field, tractors ranging from 33 H.P. to 65 H.P. Tractors for specialized needs-Rice special tractors, pudding special tractors and tractors for forest applications, being some of them. These specialized tractors have contributed towards high yield in paddy by 20%, sugarcane by 20%, wheat by 90% and Maize by 72%. Constant emphasis on research has led to development of important industrial products like dozers.

INDOFARM tractors are designed to suit almost any agricultural application like ploughing, harrowing and tiling and the tractors can be with variety of attachments for leveling, dozing, belt pulley operation etc.

THE LATHE
Lathe is a forerunner of all the machine tools. It is a machine used to perform various round works. The work piece, held by a work holding device mounted on lathe spindle, is revolved against a cutting tool, which produces a cylindrical form. Its basic principle is that work piece is held and rotated on its axis while cutting tool is advanced along lines of a desired cut.

It may be used to perform various operations such as: 1.Turning. 2.Facing.

3.Drilling. 4.Tapering. 5.Boring. 6.Threading. 7.Knurling. 8.Threading. 9.Screw cutting.

INSTRUMENTS AND TOOLS USED

1. VERNIER CALLIPER. 2. SCREW GAUGE (MICROMETER) 3. THREE JAW CHUCK 4. FACING TOOL 5. TURNING TOOL 6. GROOVING TOOL

FITTING SHOP
INTRODUCTION:

In fitting shop, proper shape and finishing of specimen is done. There are various tools used in fitting shop, which perform these operations. This shop is very important as various metal pieces are given proper shape and finishing for further operations as turning, milling etc. Thus, a fitter should have complete knowledge of tools used and operations performed in fitting shop. Tools used in fitting shop are: 1.Measuring tools. 2.Cutting tools. 3.Surface measuring tools.

1.Measuring tools: These tools are used for measuring various sizes or
comparing different sizes of identical parts to check their mating or to check errors in their manufacturing. These are further classified as: a. Vernier caliper: - It is used for checking internal or external measurements of different articles. They are made in lengths of 150, 200, 300, 400, 500, 600, 800, 1000 and 1200 mm sizes. b. Vernier Depth Gauge: - It is similar to vernier caliper except that it is used to measure depth of holes or thickness of components. c. Micrometers: - These are designed for measurements having accuracy up to 0.01 mm.

2.Cutting Tools: They are used to remove metal from blanks in form of blanks in
form of chips to bring it to desired shape and size. Commonly used cutting tools are: a. Chisel: They are used for chipping and cutting away metal. Forging, rough grinding, hardening and tempering make them. The cutting angle varies between 35 and 70. b. Files: - File is a hardened piece of high-grade steel with slanting rows of teeth cut on it. The teeth are cut with a sharp chisel having a point angle of 55 to 60. c. Hacksaw: - It is an important tool used to make long cuts. It consists of a blade having cutting teeth fixed to a frame, which may be adjustable or non-adjustable. The blades are either made of carbon or high speed steel. d. Scraper: - It is used to remove metal flake by flake from a surface to make it fine and smooth. It removes thin chips. e. Drills: - These are used to produce round holes in metal. These are mainly of three types:

I. Flat Drill. II. Straight flute drill. III. Twist Drill. Out of these, twist drill is most commonly used.

f. Reamers: These are multitoothed tools used for finishing and enlarging previously drilled hole. These are classified accordingly to operation, purpose and shape as: I. Parallel head reamer: - It has cutting edges parallel to axis with front teeth slightly tapered for easy operation. II. Parallel machine Reamer: - It is similar to above reamer except length of teeth is small and has a straight parallel shank. III. Taper pin reamer: - The fitting edges are tapered for hole to suit pins with a taper of 1 in 50. g. Scriber: - It is a piece of harden steel about 150 to 350 mm long and 3 to 5 mm in diameter pointed on both sides like a needle. One side is generally bent at right angles. This side is used to scratch lines in places where straight portion cannot reach.

h. Spanners: - These are used for scribing circles, marking off and lengths.

3. Surface measuring tools: These are used for checking deviation of a surface from horizontal or vertical plane and for checking straightness of surfaces.

Spirit levels are most commonly used for testing surfaces. In the process of checking, spirit level is placed on surface to be checked and deviation is read off scale in the glass tube. Placing level at several points checks long parts.

LIGHT MACHINE SHOP

INTRODUCTION: As the name suggests, all the light part used in the tractor assembly are manufactured in this shop.

STRUCTURE:

This shop can be divided into three sections. These are:

a) Auto section b) Gear section c) Tool room

COMPONENTS MACHINED:
In this section, manufacturing of steering and auto parts is done. Auto parts include, shifting fork assembly differential assembly parts and lay shaft. Different assembly parts include planet pins, Gearshift lever assembly, Pivot assembly and binder and tractor fork. Steering parts include: - pivot, LH Steering arm, RH Steering arm, steering nut assembly, Steering head.

MACHINES INSTALLED:

1.STC-25 2.Cemtre Lathe 4.Turret lathe

5.V Milling 6.Theard Milling 7.Horizontal Milling 8.Horizontal Broaching 9.Vertical Broaching 10.Straightening machine 11.multispindle Drilling 12.Radial Drilling 13.Bench Grinder 14.Centre less Grinder 15.Surface Grinder 16.Cylindrical grinding machine 17.Interal Grinding machine

OPERATIONS PERFORMED: Milling, Drilling Thread, Turning, Threading, Boring, Copy Turning, Reaming, Keyway milling, Cylindrical grinding, Internal grinding, Centre grinding, Surface grinding, Copy grinding, Copy grinding, Centre less grinding, Straightening, Fitting, Washing, Tapping.

HEAVY MACHINE SHOP INTRODUCTION:

In this section, all heavy parts of tractor are machined. Machining of gear box housing, main transmission housing, front cover, hydraulic lift etc. is done on various machines installed on this section.

MACHINES IN THE SHOP:

All the machines in this section are special purpose machines i.e. machines which perform special or specific operations on job and no other operations can be done on it. The advertising of using SPMs is that it increases rate of production. Every SPM has its own jigs and fixtures. The machines are capable of machining any number of identical parts in very less time.

DUPLEX MILLING MACHINE:

This machine can face or mill two sides of job simultaneously. There are two separate motors for two cutters, feed motor is used for table feeds motion, clamping of job in the fixtures is hydraulic. In this motion, table has no up and down motion but it has transverse movement only. Cutter gives depth of cut. MULTI SPINDLE DRILLING MACHINE It has 20 spindles and can drill 20 holes in job from single motor shaft. Power through gear box is transmitted to various spindles through set of gears. All drills rotate with different speed and have different diameter. Type of drill is selected according to speed or RPM from gear box and motion comes to various drills through universal joints. Because of these joints, drill can be located in jig in any position, then job is fixed and drills are fed into job. Speed of drill can be changed through various combinations of gears.

TOOLS :
The milling cutter is a multi point revolving cutter tool. The teeth of milling cutter may be parallel to axis or at an angle known as helix angle. Helix may be right or left. Various types of cutter used in this machine are: 1.Plain milling cutter- This cutter has straight or helical teeth. They are used to machine flat surfaces.

2.Face milling cutter- It is also for machining flat surfaces. 3.Plain cutting saw-It resembles plain milling cutter but has small width. It is used for cutting-off and slotting operations. 4.Side milling cutter-They has teeth on their periphery and also on one of its sides. It may have plain, helical, staggered teeth. 5.Angle milling cutter-These cutters has their cutting teeth at an angle. Single angular cutter is used for cutting dovetail. 6.T-slot cutter-It is used to make T-slots. 7.End mill cutter-They has teeth on their ends as well as at periphery. Teeth may be stretched or helical. These are used for light milling operations like cutting slots, machining accurate holes for profile milling operations.

OTHER MACHINES:
1.Radial drilling machine. 2.Two-way multi spindle H2 drilling machine. 3.Simplex milling machine. 4.Special milling machine. 5.External cylindrical grinder. 6.Three way boring machine.

HORIZONTAL BORING MACHINE:

A horizontal boring machine has a bed, headstock, end supporting column, saddle and table. On horizontal boring machine, different operations are carried out. On first machine, bores are finished. WOTAN, Germany, manufactures it. The work pieces come from planning section and have at least one machined surface, thus clamping on table easy. All boring machines have two table moments, on head moment and a quill moment. Some machines are for roughening whereas other for finishing. HMT has a digital read out commonly known as Dro, which gives two readings, one for longitudinal moment of table and second for up and down movement of head. WOTAN has been provided with a lens micrometer at bottom of table so as to read accurately. In addition to this, six radial drilling machines of different size are used for producing holes, bores, counter bores, spot facing, tapping etc.

BORING TOOL BARS:

Most of the tools are either carbide tipped or have high-speed steel. These tips are secured to bars or tools, which can be adjusted to give cuts of different sizes with help of special arrangements. Various boring tools and bars in this section are: 1.ANGULAR BORING BAR: It is used for boring long and deep holes. In these holes, lead screw rotates.

2.LONG BPORING BARS: It is a long bar which holds reamer for reaming deep holed bores. 3.HOLE MILL HOLDING BAR: Hole milling is done for perfection, whre much accuracy is not required. 4.CENTER BORING TOOLS: It is used for finishing drilled or rough bore holes. 5.SHELL REAMER: It is similar to shell and mil cutter in construction. For large sized holes, machine reamer is used up to 30% and above that, shell reamer is used. 6.SPECIAL PURPOSE TOOLS: These tools are used for specific purposes like simple facing, grooving inside the bar.

PARTS MACHINED IN HMS:

1.Gear box housing. 2.Main transmission housing 3.Front cover 4.Hydraulic lift 5.Gear box cover 6.Gear shaft bearings. 7.Top cap, bush, and flange. 8.Front wheel hub cover. 9.Front cover.

10.Left hand Bushing. 11.Brake drums. 12.Gear box front cover. 13.Flange used in MT housing.

INTERNAL CYLINDER GRINDER:

It is a semi automatic, hydraulically operated high precision machine for grinding cylinder, tapered and blind holes. Both table speed and in feed of wheel are hydraulically controlled and are infinitely variables, dresser provided on the machine does diamond. It is used for grinding bushes.

HONING MACHINE: Honing is a process of producing very accurate finish

inside the hole of the job. This machine is used to do the honing inside the hole and distribute oil in cylinder of hydraulic lift of tractor. A diamond hone is used, which gives super finishing to interior of hole.

WASHING MACHINE: It is used for washing the finished and machined

components to remove oil, lubricant, coolant, chips etc. from it. After washing of components, these are sent to assembly line. A chemical solution sodium hydroxide falls on pieces in a row and cleans them completely. After washing of components, these are dried.

HEAT TREATMENT & METALLURGY

HEAT TREATMENT: Heat treatment is a combination of processes involving
heating and cooling of a metal so as to change its characteristics. Different processes done in heat treatment shop are: 1. Hardening 2. Case hardening 3. Annealing 4. Tempering 5. Quenching 1.HARDENING: It is a process in which specimen is heated 30-40C above the critical temperature and held at this temperature and then rapidly quenched in water, oil or molten salt bath. It increases the hardness and brittleness. In order to reduce brittleness and to make a specimen for proper use it must be tempered after hardening. Actually, the BCC structure of the iron changes to the FCC which in turn provides large sites to the carbon atoms so that they can easily settled or penetrate into them for getting a better hard structure. The steel obtained from this process is called high or medium carbon alloy steel or through hardened steel. Further in order to enhance the core strength alloying elements like Mn, Si, P, Cr etc. are introduced.

2.CASE HARDENING: Case hardening is a process in which iron is heated in presence of a solid, liquid, or gas rich in carbon so as to deposit the carbon atoms on the surface of iron. The deposition of carbon on the surface of iron is achieved by means of reaction of steel surface with carbon rich solid, liquid or gaseous substance above austenizing temperature (900-930C) resulting in formation of ferrous carbide or cementite (Fe3c) on it. Greater the deposition of carbon on the surface greater will be its hardness. The depth of penetration of carbon from the surface is known as Case Depth. The steel obtained after the case hardening is low carbon alloy steel having toorsto-martensetic structure. There are mainly three case hardening processes done in heat treatment shop; A. Gas carburizing B. Liquid carburizing C. Cyaniding D. Induction hardening 3. ANNEALING: It is a process in which steel is heated to temperature above critical temperature (1000-1200C) and is held at this temperature for prolonged periods, usually 10-20 hours followed by slow cooling. Annealing is done in order to soften the metals and improve its machinability. Annealing helps in defining grain size due to phase recrystallisation and also increases the ductility of metal.

4. TEMPERING: It is a process in which hardened quenched steel is heated between room temperature and critical temperature of the specimen for a certain length of time followed by air cooling. It is done in order to reduce brittleness and to remove internal stresses. Hence tempering process is carried out to increase toughness and decrease the hardness and also to stabilize the structure. 6.QUENCHING: Quenching can be described as an operation that provides for rapid cooling of steel from high temperature at which the steel is all austenite, to some lower temperature, such as room temperature. Rapid cooling is obtained by immersing the austenised steel in quenching bath. These baths may contain air water, various kinds of oils like metaquenching oils, brines, molten salts and molten metals such as lead and tin.

The various furnaces in which these processes are done:

A. Sealed Quenching Furnace B. Hardening furnace and quenching press (for crown wheels) C. Muffle furnace a. Induction hardening machine b. Pit tempering furnace c. Cyaniding furnace

A.SEALED QUENCHING FURNACE: In this furnace carburizing, annealing, hardening and quenching is done. CONSTRUCTION: 1. CHAMBERS: There are two chambers i.e. front chamber and heating chamber. In heating chamber, specimen is heated due to heat produced by the six heating elements. This process takes about three and half hours and at 920C. The provisions of gases are also present for carburizing. In front chamber annealing and quenching is done. It has metaquencher oil at the bottom for quenching purpose. The annealing is done at the upper part of the front chamber. 2.ELEVATORS: There are two elevators in front chamber, which are used to perform two operations simultaneously i.e., annealing the specimen and quenching of specimen. The specimen to be carburized is fed into the heating chamber with the help of trolley and upper elevator present in the front chamber. There is another elevator, which takes the specimen below front chamber into the quenching sump, which has metaquencher oil for quenching. It should be noted that quenching oil should have high fire and flash points.

3.ELEMENTS: The furnace consists of six heating elements, three on each sides of the heating chamber. These elements provide heat for annealing, carburizing, hardening etc. 4. PROPELLER FAN: A propeller fan is provided at the top of the heating chamber for the proper circulation of heat through gases. It helps in uniform heating of the specimen. 5. L.P.G. TORCH: It is a cylindrical torch meant for supply of L.P.G. Due to burning of L.P.G., fire is produced which provides shielding to the front chamber from atmospheric contamination. 6. SOLENOID BURNERS: These are provided in a row in the lower portion outside the front chamber. L.P.G. is also provided through these burners, which are ignited by means of fire through torch. The burners in combination with the L.P.G. torch provide a shielding wall, which prevents the penetration of atmospheric air into the front chamber. The main purpose of the fire-shielding wall is to avoid the combustion of L.P.G. in the heating furnace due to penetration of air. It may also

cause the oxidation of C and CO to form CO2 and restricts the hydrogen molecules to come in direct contact with atmosphere to avoid blast. 7.NITROGEN SYSTEM: In nitrogen system, atmospheric air is sucked by compressor and then fed to the containers comprising of molecular sieves, which separates nitrogen from the other gases. This nitrogen is further filtered in another container and then stored in the nitrogen surge vessel. 8.METHANOL CHAMBER: Nitrogen from the surge vessel is heated with the help of heaters and then mixes with the liquid methanol coming from the methanol chamber. The hot nitrogen vaporizes the methanol to its dew point and then it is further heated to dryer state by again passing it through heaters during outgoing. Now nitrogen carries dry methanol vapors to heating chamber of SQF through the delivery pipes. Hence, nitrogen can be regarded as carrier gas.

WORKING OF SQF: Firstly, the specimen is placed on the grate of the heating chamber with the help of elevators and trolley, and then heating chamber is sealed or closed by a sealing door. Here the specimen is heated to the required

temperature with the help of heating elements and propeller fan. If the specimen is to be carburized, then the nitrogen gas containing methanol vapors along with it is blown into the heating chamber through delivery pipes. At this elevated temperature, nitrogen and methanol reacts with each other to produce CO. The CO, thus produced is further used to provide nascent oxygen for the cracking of L.P.G., which is provided in the heating chamber between 900-930C temperatures from the L.P.G. container. As methanol and nitrogen produces CO (which is itself a reducing gas), hence these help in producing reducing atmosphere in the heating chamber. The cracking of L.P.G. provides carbon atoms for surface hardening. These carbon atoms react with iron and forms Fe3C (cementite) on the surface of the specimen. Greater the blow time of L.P.G. in heating chamber, greater will be the case depth of the specimen and vice versa. The specimen to be only hardened is heated in the heating furnace up to the hardening temperature in the absence of all gases mentioned above. After heating the specimen in the heating chamber, it is directly quenched in the metaquencher oil at front chamber. For the annealing of specimen, it is brought to the top of the front chamber through elevators. The top portion of the front chamber has sufficient temperature for annealing. Specimen is then cooled at very high cooling rate from the annealing temperature by reducing its temperature 3-5C per hour.

** NOTE: Previously, endogas generator was used instead of nitrogen system.

But this system requires very high temperature and also requires catalyst change after every 6-9 months so endogas generator is not adopted now days. DESCRIPTION OF ENDOGAS GENERATOR: In endo gas generator, air and L.P.G. in the proportion of 10:1 are compressed at 1040C, which results in further disintegration of L.P.G. in the presence of Ni catalyst into CO2, N2 and H2. The above reaction is endothermic hence the gas thus produced is known as endogas. The gas so produced should be suddenly cooled otherwise it will again form air and L.P.G. The nickel catalyst is protected from water by placing it in retorts as it gets destroyed when it comes in contact with moisture. The endogas thus produced is introduced into heating chamber of SQF, where it combines with methanol to keep the atmosphere of the heating chamber reducing. This environment causes the reduction of L.P.G. to form carbon atoms.

C. HARDENING FURNACE & QUENCHING PRESS:

This special unit is mainly used for hardening of crown wheel, which is further mounted in M.T. Housing of tractor. In hardening furnace, crown wheels are heated up to hardening temperature i.e. 920 C and then, placed in quenching press. There is ram present in quenching press consisting of a die having teeth opposite to the crown

wheel teeth. The ram is adjusted in such a way that its teeth mesh with the teeth of crown wheel placed in the quenching press. A hydraulic pressure through pistons is provided in the hollow space of the crown wheel in order to prevent it from shrinkage and distortion. Now on the application of pressure through ram a limited supply of oil is provided for the quenching of the crown wheel. This is done to avoid the brittleness of crown wheel material.

D. MUFFLE FURNACE:
This furnace is mostly used for the tempering of tractor parts. The parts to be tempered are placed in the muffle furnace and heated up to 300-400C above the room temperature. After heating it is cooled at pre-determined rate. Tempering is done in order to remove the internal stresses produced during the cold working processes. The furnace generally consists of heating elements for the heating of specimen enclosed in a thick glass wool.

E. INDUCTION HARDENING MACHINE:

This machine is generally used for case hardening of certain parts of the specimen. Parts to be case hardened are surrounded by the induction coil carrying higher current. Attaching step-down transformer to the main supply provides this higher current. When the current circulates in the induction coil, it induces opposite eddy currents on the surface surrounded by it. Due to the heating effect of eddy currents case hardening occurs

at the specific surfaces where eddy currents are induced. The heat produced due to flow of eddy currents on the surface of specimen is given by; H=I2RT Where, H = Heat produced due to eddy currents, I = Magnitude of eddy currents, R = Resistance of the surface, T = Time for which current flows on the surface.

F. PIT TEMPERING:
This furnace is also used for the tempering of the tractor parts. It consists of dome covered on a pit having diameter slightly greater than the pit diameter. Pit dug in the floor has an equal depth as that of the dome above the floor. The main function of dome is to isolate the tempering furnace from the external atmosphere. There are heating elements provided in the pit for the heating of components. The pit is internally covered with highly heat resistant surface like firebrick lining or glass wool covering so as to withstand high temperatures and also to provide internal support to the pit. The specimen to be tempered is placed in a wire basket made up of refractive material so as to heat the

specimen uniformly from all sides. A propeller fan is also provided at the top of dome in order to circulate heat properly through air.

G.CYANIDING FURNACE:
It involves heating of parts in molten cyanide salt maintain at temperature of 800-850C and then quenching it in oil bath. The salt bath contains sodium cyanide, soda ash and sodium chloride in the proportion varying from 25 to 40 %. Cyaniding time is determined by depth of hardened case required and varies from 5-20 minutes. The resulting case contains 0.6-0.8 % carbon and 0.4-0.5 % nitrogen. The hardened depth obtained from this operation varies from 0.075-2.5 mm. Coupling thermometer is dipped in the salt bath to measure the temperature of the salt solution.
OTHER MACHINES USED IN HEAT TREATMENT SHOP

1.SAND BLASTING MACHINE:

It is used for removing carbon film from the surface of component. There are two impellers which blows sand with very high pressure on the rotating component placed in sand blasting chamber. These impellers blow sand from two opposite radial directions. Due to sand jet, carbon film is removed from the surface of component. 2.COPPER PLATING:

It is the process in which copper coating is done on the component after its degreasing. Degreasing is done to remove oil for efficient copper plating. It is done on the components, which have to sustain high temperature. Copper gets deposited as the component is dipped in copper salt solution. The component after copper plating is dried in vertical oven to remove moisture from it. 1.WASHING MACHINE: The component after heat treatment is placed in the washing machine for proper cleaning of the surface. It removes dust, carbon, oil etc. from the component placed in it. Caustic soda with water is used as washing agent and the solution is kept at 50C.

METALLURGY SHOP
INTRODUCTION:
In metallurgy shop, testing of various components of the tractors is done so as to check composition and mechanical properties of their elements. Here, hardness of materials, strechability of springs, chemical composition of material, loss of ignition, deformation in pipes, viscosity of non-volatile material are tested. There are different sections and different apparatus, which are used to perform these operations.

1. CARBON APPARATUS: In this process, combustion boat is used which is made up of ceramic material and can withstand 1200-1300C of temperature. It is used to check the fixed carbon in the given specimen. A small piece of material to be tested is placed on the combustion boat, which is inserted inside the combustion furnace (containing electrodes for heating the combustion boat externally) with the limited supply of oxygen from front end through oxygen cylinder. Due to improper burning CO is produced and it is collected in the glass tube through a pipe. Then

this CO is washed with KOH solution due to which the fixed carbon get collected in a graduated glass tube whose level can be easily designated with the help of coloured solution. Hence by knowing the amount of fixed carbon we can detect the hardness of the given specimen.

2. ELECTRIC FURNACE:
It is used to check strechability of springs. Here, elongation test is also performed to check plastic deformation, ductility, and brittleness. The spring to be tested is placed in stressed position in between two clamps and then heated to a temperature above the working temperature for two to three days. Now, material with elastic deformation is selected and the materials, which show plastic deformation, are rejected.

3. CHEMICAL SECTION:
In this section, materials are tested for chemical composition. Different test are performed to detect the presence of different alloying elements such as Mo, Zn, Cr, P, Si, Mn, Ni, S. Each alloying element enhances the particular characteristics of the steel e.g., Manganese helps in increasing the hardness and wear resistance.

4. RUBBER SECTION:
It is used to check deformation and loss of ignition (L.O.I.) of hosepipes and gaskets. Here, Ageing oven is used in which the

specimen is placed for 72 hours. The temperature is maintained at 70-80C and the specimen is then removed. Now the material is checked, whether elastic or plastic deformation occurs and how much of material is burnt at high temperature. The materials, which shows elastic deformation and have less value of L.O.I. is desired.

5. PAINT SECTION:
Here, viscosity and presence of volatile material is tested. The paint to be tested is treated with various chemicals, which shows the presence of volatile material. The viscosity of the paint is tested using Redwood viscometer. Higher viscosity of paint is desired.

6. SPECTROSCOPE:
It is used to detect the presence of elements and composition of the elements. Material is placed on the spectroscope and the monochromatic light rays emitted by the spark produced by the roller electrode cause the formation of colored patterns which can be seen with the help of microscope. Each pattern showing the presence of particular element in the specimen and the thickness of the pattern just gives the idea about the percentage of that element.

7. SPECTROGRAPH:
The specimen is placed between two electrodes of the apparatus and spark of light is produced using Argon gas flow. Now, the light rays produced from this spark are made to strike on the specimen and diffraction of light is observed. Different intensities of diffraction shown by different elements are observed which shows their presence and hence their composition. Intensity of diffraction shown by the different elements depends upon type of bonding and molecular structure of elements. This whole record is displayed on the monitor. 8. ANALYSER: It is used to check the presence of cementite, pearlite etc. It uses a microscope in which the microstructure of the element is magnified (magnification factor = 100) and is compared with the charts showing actual structure of cementite, pearlite etc. which gives the required information. It is also used to check depth of case hardening. It can magnify maximum 650 times the original structure.

9. CRACK TESTING MACHINE:

It is used to detect the presence of cracks present in the specimen. Test specimen is placed between two ends of the machine and magnetic field is applied on it, which leads to formation of opposite poles at

the location of cracks. Now, ferrous sulphate particles with a fluorescent die are sprayed on it, which sticks to the ends of the poles. UV rays are allowed to fall on the specimen and cracks undergo glow or fluorescence. These are then noted and then eliminated. Now, specimen is demagnetized using demagnetizer and is removed.

10. BRINELL HARDNESS TESTING MACHINE:

This test is done in order to test the hardness of soft materials and hence materials are checked before their heat treatment . In this test a standard steel ball is pressed into the surface of specimen by a gradually applied load, which is maintained on the specimen for definite time. The impression so obtained is Measured by microscope and brinell hardness no. is found out by following equation: B.H.N. = = Load
Area of impression/indentation

2P 3.14 D (D- (D2-d2)) Where, P = load (kg) D = Diameter of ball (mm) d = Diameter of indentation (mm)

11. ROCKWELL HARDNESS TEST: It is used to check hardness of hard

materials and hence the components are tested after heat treatment. The specimen is held placed on anvil of machine and penetrator seated by means of 10 kg minor load. The dial indicator is zeroed and then a major load of 60, 100 or 150 kg is applied. On removal of major load, the indented specimen recovers, and final depth of penetration is registered directly on dial indicator as a hardness number. There are two scales viz. HRB and HRC, respectively for 1/16 ball with 100 kg load, and diamond penetrator with 150 kg major load. Hardened alloy steel has HRC of 55 and mild steel have HRB reading of 90.

12. VICKERS HARDNESS TEST: Here, a polished square based pyramid

diamond tool with an angle of 136 between faces is used. This tool under gradual load makes an impression on specimen. The load divided by area of indentation in mm2 gives pyramid hardness number. D.P.N = 2P sin 0/2 D Where, P = load in kg, 0 = Angle between opposite faces, D = Mean length of two diagonals in mm.

13. SPRING TESTING MACHINE:

This machine is used to detect the deflection of springs after the removal of tensile and compressive loads, which were applied during testing for a certain time interval. If the deflection is in limits then they are selected otherwise they are rejected.

14. PORTABLE TESTER:

This is actually a microscope. It is used to check the microstructure of material so as to check the composition of pearlite and ferrite in the material of a component. The main advantage of this test is non-destructible test.

FOUNDRY SHOP

INTRODUCTION:

Foundry is known as the mother of manufacturing technology field .It is the place where the basic small or large size solid parts of various types of mechanical machines. The parts, which are required to be durable, and having high strength are prepared in this shop. Foundry is a place where castings are made by pouring molten metal into cavity prepared by pattern. In INDOFARM tractors foundry shop, castings of gearbox, cylinder head, M.T. housings, front and rear axles etc. are made. All casts are made from gray cast iron. Various processes involved in foundry shop are mould preparation; core making, knock out process, Decoring, fettling and priming. Schematic description of various processes done in foundry shop are:

MOULD PREPARATION

POURING

KNOCK OUT PROCESS DECORING FETTLING PRIMING DESPATCH

1.MOULD MAKING:
In mould making process, green sand is used and moisture should be there at time of pouring molten metal. Light castings are made by using green sand mould and heavy castings are made by using dry sand mould is used. Machine used for making mould is Squeeze zolta machine and systems used are pneumatic and hydraulic. 1-1.5% bentonite is added as a binder material so as to increase the binding properties of moulding sand. In order to increase the permeability cushion material in the form of bentokol(0.25%) is used. 3.8-4%

moisture is also added in order to increase the strength of mould. The combination of all constituents is known as system sand. The mould hardness number is 93-94. Green compressive strength of mould is 1000-1200 g/cm2. COMPOSITION OF GREEN SAND: Green sand consists of silica sand having washed silica (quartz) parts with uniform grain size. After molten metal is poured into mould, 90-92% silica is recycled and 8-10% of fresh sand is added to maintain quality of sand. Permeability number is 180-200.

2.POURING:
After mould is prepared, molten metal is poured into it slowly from laddle. This process is done with the help of E.O.T. (overhead crane). The molten metal is then allowed to cool and solidify.

3.KNOCK OUT PROCESS:

In this process, casting is separated from mould. It is done after the cooling of molten metal. The mould is placed in knockout chamber and is then shaked after which casting is separated from the mould.

4.DECORING:

In this process, core is removed from the casting manually. The waste core sand is used as backing (supporting) sand so as to support hollow cores and increase the refractoriness.

5. FETTLING:
In fettling section, shot blasting and grinding is done. Grinding is done in order to remove the irregularities in the casting and shot blasting is done to remove sand from the casting. A.SHOT BLASTING: It is done to separate the sand from the casting, which sticks to it during the casting process. In this process, the casting is rotated in a shotblasting chamber and then small iron shots are blown on to the casting through impeller, which is rotating at 3000 r.p.m. These shots grind out the sand from the casting. B.GRINDING: After shot blasting, grinding is done for proper finishing and shaping of the casting. It is done with the help of grinder.

6. PRIMING: It is a painting process done on the casting so as to protect it from deterioration by the external atmospheric conditions. It also protects it from corrosion.

7. DISPATCH:
In dispatching process, the casting is dispatched to the other shops for its further processing.

OTHER IMPORTANT PROCESSES PERFORMED IN FOUNDRY SHOP: CORE MAKING PROCESS:

In this process, different cores are made for the castings of different parts of tractor. It is done by two processes: 1. BAKING PROCESS: In baking process hollow and solid cores are made by pouring and baking the shell sand (dry silica sand+resin of hexa powder) into the permanent mould of core machine. The process proceeds in following steps: A.Blow time: It is the time taken by the sand to reach the machine hopper from the sand chamber.

B. Investment time: It is the time during which some sand is poured from the hopper into the permanent mould so as to form the outer layer of core. C. Sand feed time: It is the time in which sand is fed properly into the mould to fill it completely. D. Rock time: In this time, the mould is shaked a little bit so that the sand gets properly settled in the mould in order to form the hollow core. E. Curing time: It is the time for which the core is baked up to the curing temperature in the permanent mould. PROCESS . sec CYCLE-TIME (Gear box hsg.) CYCLE-TIME 2522/3522 CYL.HEAD COMMON BLOW TIME 3-5 3-4 sec 25-30 sec 15-18 sec 60-70 sec 15-18 sec 55-60 PSI 240-260 C 14-16 sec 0 40-50 sec 12-15 sec 55-60PSI 240-260C

INVESTMENT TIME ROCK TIME CURING TIME SAND FEED TIME BLOW PRESSURE CURING TEMP.

2. NO-BAKE PROCESS: It differs from the bake process that here dry sand is used for making no bake sand which is further used to form the core. It is then finally baked in a vertical oven so as to harden the core to avoid its collapsing or bending. Materials used in NO-BAKE process:

1. Binder 2. Catalyst 3. Hardener 1. 4. Dry silica sand The proportion in which above constituent are mixed is as follows; Hardener = Binder/4; Catalyst = Hardener/5; PROCEDURE: Dry silica sand is introduced into the no bake machine, which is then mixed with binder, catalyst and hardener and resultant mixture is rotated in the no bake chamber for intimate mixing of components. This whole process takes three minutes and is known as batch mixing time. Now the sand is collected which is no bake sand and is taken to the core-making site where the permanent moulds are placed. This process takes about 5-8 minutes and is known as bench life. No bake sand is fed into the permanent moulds and allowed to strengthen to about 40 minutes and is known as strip time. Now, the resultant core is again baked in the vertical oven so as to increase the hardness of the core. **OVEN: It is a furnace used in the foundry shop for removing the moisture and to increase the hardness of core inserted into it. These are of two types:

A. Horizontal oven: It is used for baking small cores. It takes less time B. Vertical oven: It is used for baking large sized cores and takes more time. It is comparatively more expensive and is less expensive. Sr. no. 1. 2. 3. 4. 5. 6. 7. 8. MATERIAL Dry Sand Part A Part B Part C Scratch hardness Batch mixing time Bench life Strip time ADDITION 120 kg 2.5 3 kg 5 % of part A-150g 20 % of part A-600g 80-90 No. 3 mts. 5-8 mts. 40 mts.