CHAPTER 1 FOUNDARY SHOP

MELT SHOP
This department is engaged in preparing the molten metal, which has to be ultimately poured in green sand mold to produce a casting. Before pouring into the mold, the metal to be cast to be in the molten or liquid state. An IND !TI"N # $NAN!% is used for melting the metal. The selection of a furnace depends upon the followings factors. Initial cost of furnace. #uel costs. &ind of metal or alloy to be melted. 'elting and pouring temperature of the metal to be cast. (uantity of metal to be melted. 'ethod of pouring desired. !ost of melting per unit weight of the metal. #le)ibility of the unit. !ost of the finished product desired. *peed of melting the alloys. Degree of cleanliness or pollution.
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 Degree of control required. There is one melt shop. There are two induction furnaces, and these furnaces are of main frequency ,-. cycles/sec0 #urnace no.1 1 !apacity1. - tons #urnace no. + 1 !apacity1. - tons

INDUCTION FURNACE
Introduction: An induction furnace is an electric furnace in which the heat is applied by induction heating of a conducti3e medium ,usually a metal0 in a crucible around which magnetic coils are wound .The ad3antages of the induction furnace is a clean ,energy efficient and well controllable melting process compared to most other means of metal melting .'ost modern foundries use this type of furnace and now also more iron foundries are replacing cupolas by induction furnaces to melt the cast iron , as the former emit lots of dust and other pollutants. Principle of Induction Furnace: Induction is the production of electric charge, magnetism or electromoti3e force in an ob4ect ,as an electric conductor, a magnetically body, an electric circuit0 by the pro)imity without contact of a similarly energi5ed body of the 3ariation of a magnetic flu). %ddy currents induced by a 3arying electromagnetic field accomplish induction heating and melting .The current is caused to flow through the material to be heated or melted ,or through induction. Induction heating Induction melting
6

its

container,

i.e.,

crucible0

by

electromagnetic

Induction

eatin!:

Induction heating is the process of heating a metal ob4ect by electromagnetic induction, where eddy currents are generated within the metal and resistance leads to 4oule heating of the metal. An induction heater ,for any process0 consists of an electromagnet, through which a high frequency A! current is passed . 7eat may also be generated by magnetic hysteresis losses. Induction heating allows the precision heating of an applicable item, for applications from surface hardening to melting, "ften ,iron and its alloys respond best to induction heating , due to their , ferromagnetic nature. %ddy currents can, howe3er, be generated in any metallic conductor, and magnetic hysteresis can occur in any magnetic material. Induction "eltin!: Induction melting also uses electrical eddy currents induced in the charge to heat and melt metal by its electrical resistance. This is accomplished by electrically coupling the charge with the alternating current coil. Induction is widely used in the production of iron and steel castings, for melting aluminium, 5inc, copper, and a great 3ariety of other nonferrous alloys. Induction furnace: An induction furnace uses induction to heat a metal to its melting point. "nce molten, the high frequency magnetic field can also be used to stir the hot metal, which is useful in ensuring that alloying additions are fully mi)ed into the
-

melt .'ost induction furnaces consist of a tube of water cooled cooper, rings, surroundings a container of refractory material. Induction furnaces are used in IND"#A$' %( I8'%NT 9I'IT%D, as a cleaner method of melting metals than a re3erbatory furnace or a cupola .*i5es ranges from hundreds of :ilograms capacity, to ten tonnes capacity. Induction furnaces often emit a high pitched whine or hum when they are running, depending on their operating frequency. 'etals melted include iron and steel, copper, aluminium, and precious metals. Con#truction: The two most common induction melting furnace designs are; !oreless furnaces !hannel furnaces !oreless melting furnaces use a refractory en3elope to contain the metal, and surround that by the coil. "peration on the same basis as the transformer , the charge act as a single secondary tern, there by producing heat by eddy current flow when power is applied to the multi turn primary coil. Induction channel furnaces were used initially as molten metal holders, but are now used for some melting applications as well. An inductor, comprised of a water cooled coil, is the energy source. A channel is formed in the refractory through the coil, and this channel forms a continuous loop with the metal in the main part of the furnace. The hot metal in the channel circulates into the main body of the metal in the funace. The hot metal in the channel circulates into the main body of the metal in the furnace, source of primary molten metal is required for the

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starup of a channel furnace .These furnaces do ha3e lower surface turbulence within the main metal bath. !oreless furnaces are preferable where gas pic:up and 3olatile metal alloy loss is a problem. !hannel induction furnaces are often selected for holding metal at temperature. =hile all channel furnaces are line frequencies ,+.. 75 through 1+.. 750 or high frequency ,o3er 1+.. 750.9ine frequency furnaces are slower to start from a cold charge resulting in growing preference from medium and high frequency units. Impro3ements in frequency con3erters and lower costs ha3e also aided acceptance.

CORE SHOP
This shop is engaged in preparing cores, which are ultimately used in the >mould assembly? *tage of foundry process of producing hollow ca3ities in castings. This shop consists of two areas 1. !ore sand control area +. !ore ma:ing area Core: Core i# an o$#truction % ic % en po#itioned in t e "old &naturall' doe# not per"it t e "olten poured "etal to fill up t e #pace occupied $' t e core(

1. !ores are required to create the recesses, undercuts and interior ca3ities that are often a part of castings. !ores made of core sand are generally employed. Function of Core#: 1. #or hollow castings, cores pro3ide the means of forming the main internal ca3ities. +. !ores may form a part of green sand mold. 2. !ores may pro3ide e)ternal undercut features. 6. !ores may be employed to impro3e the mold surface. -. !ores may be inserted to achie3e deep recesses in the castings. <. !ores are also used to form the gating system. E##ential c aracteri#tic# of Dr' Sand Core#: 1. *ufficient strength to support itself and to get handled without brea:ing. +. 7igh permeability to let the mold gases escape through the mold walls. 2. *mooth surface to ensure a smooth casting. 6. 7igh refractoriness to withstand the action of hot molten metal.

CORE MA)IN* PROCEDURE:

!"$% *AND 8$%8A$ATI"N
A

'A&INE T7% !"$%

!"$% BA&INE

!"$% #INI*7INE

!"$% D$FINE

!"$% A**%'B9INE

!"$% *%TTINE Core Sand Preparation Sand Control: This department is engaged in preparing sand mi)tures for different types of cores that are being made in core shop. This shop consists of Base sand containersB+ Bench hoppers C 6
D

 *and mullers *and trolleys

C 1-. and

C 2-.

Bench hoppers for small cores Types of sand mi) in sand control; *hell sand mi) 7ot bo) sand mi) !old bo) sand mi) "il sand mi) No ba:e sand mi)

Fi! +,

CORE DR-IN*:

1.

The cores on which wash has been applied needs to be dried before their supply to assembly area near the :w line. #or this purpose two types of o3ens are generated used Bo) "3en Gertical "3en or tunnel "3en Gertical o3ens are used to dry small si5ed cores while bo) o3ens are used to dry large si5e cores. !ores are placed on sliding drawers, which can accommodate cores of different si5es , thic:ness and length Specification of .O/ O0EN: Time for ba:ing C 16- minutes #ront Door Temperature C 1@. to +1. $ae #ace Temperature C +.. to +6. 9eft face Temperature B +.. to +6. $ight #ace Temperature C +.. to +6. Temperature setting on controller C +2Mediu" of Heatin!: "il #rom Tan: Blower Ignition CORE ASSEM.L-: !ore assembly means 4oining together by pasting, leading or bolting two or more components parts of the core before the core can be set in the mold ca3ity.
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 !ore paste is applied o3er the core with the help of finger, by brushes or dipping. !ore paste is formed out of talc , de)trin , molasses, flour , water etc . !orepieces after being pasted , are assembled , pressed and left to dry. 9arge core parts are assembled by nuts and bolts. Nuts and bolts are of course co3ered with mud after 4oining the core parts .

PATTERN SHOP
This department is engaged in manufacturing patterns, core bo)es, 4igs, fi)tures, mold bo)es and blow plates etc. The pattern shop is equipped with 'odern Technology machines such as !'' ,!oBordinate Numeric 'easure 'achine0, Aided !N!/!A',!omputer 'achining0 etc. PATTERN: 8attern is the model of casting around which molding material is filled to produce the mold ca3ity. 8atterns are called foundary men mould forming tools. 8attern 'a:ing and Inspection; The steps in3ol3ed in the pattern ma:ing and its inspection are described as follows; Ma#ter Pattern Ma1in! : !ontrol/ !omputer

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#irst of all, a wooden master pattern is made with the help of machines a3ailable in pattern shop. The 3arious allowances are :ept in the master pattern since it is to be used for casting the actual pattern i.e. the pattern is to be used for molding purposes. The 3arious types of allowances are as follows; *hrin:age allowances. Draft Allowances. #inish or 'achining Allowance. *ha:e Allowance. Distortion Allowance S rin1a!e Allo%ance: All the metals shrin: while cooling e)cept bismuth. This is because of the interBatomic Gibrations, which are amplified by an increase in temperature. The rate of contraction is dependent on the material. The shrin:age Allowance is always to be added to the linear dimensions .%3en in the case of internal dimensions , the material has a tendency to contract towards he centre and thus is to be increased. Mac inin!: The pattern, which is mar:ed, is ready for machining. The pattern is machined by the help of 3arious with the help of !A'/!N! machine in which the gi3en 4obs is performed in the

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computer with the help of software and the machine follows the instructions deli3ered by computer and complete the 4ob. Pattern In#pection: The machined pattern is chec:ed for dimensional 3erification i.e., whether the pattern has got the dimensions as per the drawing supplied by design office. If the pattern is dimensionally "&, then it is sent for sample production. Sa"ple Production: The sample production of castings from the pattern is made if the castings are not dimensionally sound, then design is modified again and all the steps mentioned abo3e are repeated until dimensionally sound casting is obtained. Draft Allo%ance: At the time of withdrawing a pattern from the sand mlod, the 3ertical faces of the pattern are in continual contact with the sand, which may damage the mold ca3ity. To reduce the chances of this happening, the 3erticals faces of the pattern are always tapered from the parting line. This pro3ision is called Draft Allowances. Fini# or Mac inin! Allo%ance#:

The finish or accuracy achie3ed in sand casting are generally poor and therefore when the casting is functionally required to be of good surface finish or dimensionally accurate, it is generally achie3ed by subsequent machining. 7ence e)tra material is to be pro3ided which is to be subsequently remo3ed
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by machining or cleaning process. The type of machining allowance pro3ided would depend upon the metal cast, the type of moulding used, the class of accuracy required on the surface and the comple)ity of surface details. S a1e Allo%ance#: Before withdrawal from the sand mold, the pattern is raped all around the 3ertical faces to enlarge the mold ca3ity slightly, which facilitates its remo3al. *ince it enlarge the final casting made, it is desirable that the original pattern dimensions should be reduced to account for this increase. Di#tortion Allo%ance: A metal when it has 4ust solidified, is 3ery wea: and therefore is li:ely to be distortion prone. This is particularly so far wea:er sections such as long flat portions, G, sections or in !omplicated casting which may ha3e thin and long sections which are connected to thic: sections. The foundry practice should be to ma:e e)tra material pro3ision for reducing the distortion. Ca#tin! t e Pattern: The actual pattern, which is to be used for molding purposes, is cast with the help of master pattern. The ca3ity is made by pac:ing the green or some self setting sand mi) around the master pattern and then remo3ing the wooden pattern. The molten metal is poured in the bo) in which impression of master pattern is made and after the metal poured has cooled the cast actual pattern is ta:en out of the molding bo).
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Mar1in!: The cast pattern is mar:ed by placing it on the mar:ing table as per the drawing. All the drawings are made by HDesign officeI. The design of pattern, corebo), Jigs are made by design office with the hat off !AD Mac inin! The pattern, which is mar:ed, is ready for machining. The pattern is machined by the help of 3arious sophisticated machine in the pattern shop . The final profiles are machined with the help of !A'/!N! machine in which the gi3en 4ob is performed in the computer with the help of software and the machine follows the instructions deli3ered by computer and complete the 4ob. Pattern In#pection: The machined pattern is chec:ed for dimensional 3erification i.e, whether the pattern has got the dimensions as per the drawing supplied by design office. If the pattern is dimensionally "&, then it is sent for sample production. Sa"ple Production: The sample production of castings from the pattern is made if the castings are not dimensionally sound, then design is modified again and all the steps mentioned abo3e are repeated until Hdimensionally sound Hcasting is obtained.

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Fi! +2

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MOLD SHOP
'old shop is the biggest machine in fettling as compared to other shot blasting machines as it deals with totally blac: castings e.g. %I!7%$ B9"!&, A*7"&A 9%F9AND B9"!& etc. after passing thro the sha:er it is brought to this machine. Mold Ma1in! 8repare molding sand is pac:ed rigidly around the pattern and when the pattern is withdrawn , a ca3ity corresponding to the shape of the pattern remains in the sand and is :nown as mold ca3ity. Thus a mold is sort of container which when poured with molten metal produces a casting of the shape of the mold. The process of ma:ing molds is referred to as 'oldB ma:ing. C aracteri#tic#: A "old"u#t: 8ossess refractories to bear the high heat of the molten metal. 8ossess strength to hold the weight of molten metal. 8roduce a minimum amount of mold gases.

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 Be able to resist the erosise action of the molten metal being poured. $esist metal penetration into the mold walls. Mac ine "oldin!: =hereas in bench , floor and pit molding , the different molding operation are carried out manually by hands of the molder , 3arious molding operations li:e ramming , rolling the mold o3er, with drawimg the pattern etc. are done by machines. 'achine performs these operations are much fast, more efficient and in a much better way. 'olding machines produce identical and consistent casting. 'olding machines are preferred for mass production of casting whereas hand molding is used for limited production. 'achine molding is not a fully automatic processK many operations can though be performed by machines, yet some others ha3e to be carried out by hands. A few different types of molding machines are listed below; 10 Jolt machine +0 *quee5er machine

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20 JoltBsqueer5er machine 60 *and slinger *reen #and "oldin!: It is most widely used molding process The green sand used for molding consist of silica sand, clay, water, and other additi3es. "ne typical green sand mi)ture contains 1. to 1-L clay binder, 6 to <L water and remaining silica sand. The green and mi)ture is prepared and the mold ,cope and drag0 is made by pac:ing the same around the pattern. !ope and drag are assembled and the molten metal is poured while the mold ca3ity is still green , that is it, it is dried for ba:ed. Ereen sand molding is preferred for ma:ing small and medium si5ed castings. Ereen sand molding is specially employed for produsing nonBferrous casting. Ad3anta!e: Ereen sand molding is adaptable to machine molding. No mold ba:ing or drying is required. There is less mold distortion than in dry sand molding.
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 Time and cost associated with mold ba:ing or drying is eliminated . Ereen sand molds ha3ing smaller depths permit the escape of mold gases without any difficulty. In green sand molding , flas:s are ready for reuse in minimum amount of time . Ereen sand molding pro3ides good dimensional accuracy across the parting line. Ereen sand mold in3ol3es less danger of hot tearing of casting as compared to dry sand molds.

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FETTLIN* SHOP
Introduction to fettlin! After sha:ing the casting out of mould, it is con3eyed to the fettling ,dressing0 shop for cleaning and finishing. The fettling process ,cleaning and finishing0 consist of the following operations; Decoring or core remo3al !leaning of surface $emo3al of gates, risers and fines etc. $epairs of defecti3e castings if possible and heat

treatment. Before starting the fettling process, the castings are e)amined for ob3ious defects such as misrun, drop, cold laps and cold shuts etc. Defecti3e castings are set aside are not cleaned. ,( Core re"o3al or core 1noc1out: Due to the reason mentioned under Hsha:e out operationI, this operation is also done mechanically. 7ammering and 3ibrating will loosen and brea:up cores. *tationary or portable 3ibrators are employed for this purpose. 2( Cleanin! of #urface#: This operation in3ol3es the remo3al of all adhering sand and o)ide scale and produces a
++

uniformly

smooth

surface.

'echanical methods are employed for this purpose, since cleaning by hand with wire brush in tedious and costly. These methods include; Tumbling *and blasting and shot blasting Airless shot blasting 7ydro blasting 4( Re"o3al of !ate# and %ire#: Eates, risers, and sprue can be remo3ed before or after cleaning operation. In brittle materils, these are simply bro:en off from the castings. In more ductile, materials, the following methods are used to remo3e them; 8ower hac:saw Band saws Dis: type cutting benches Abrasi3e cut off wheels #lame cutting with an o)yacetylene cutting torch Arc cutting for heat resistant and acid resistant steels

Fettlin! procedure:
EAT%* AND $I*%$ $%'"GA9 8$% *7"T B9A*TINE 8"*T *7"T B9A*TINE
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E$INDINE

=%9DINE

8AINTINE

D%*8AT!7

SHOT .LASTIN*
These method are widely used to clean surfaces of light, medium and hea3y castings. In these machines, dry and sand shots ,white !.I shot, steel shot0 or grit of white !.I or steel ,grit is made by crushing shot0 is blown by a stream of compressed air against the surfaces of the castings. The impact of the abrasi3e particles tra3elling at a high speed, on the surface remo3es the adhering sand and o)ide scale. Gelocity of the abrasi3e particles lea3ing the no55le of the machine is in the range of 2- to @- m/s and the air pressure is is the range of ..@ 'pa. *hot blasting is done for the following purposes; To clean the casting surfaces $emo3al of sand *cale remo3al

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 $ust remo3al There are three machines installed in the fettling shop for this purpose;

SHOT .LASTIN*

.MD ,

INDA.RATOR

.MD 2

+-

CHAPTER -2 MACHINE SHOP

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'A!7IN% *7"8
As the name shows all the light parts of tractors such as differential housing, power ta:e off shafts, splined shafts, gears, rear wheel dri3ing hubs, portal shafts, main transmission shafts etc. are machined here. Different operations such as turning, grinding, hobbing, broaching, milling, drilling, boring, reaming, threading etc. are performed here two type of materials are uses in light machine shop . 1. $olled steel ,in the form of bars for the manufacture of shafts0. +. #orged steel ,in the form of circular pallets for the manufacture of gear0. 9ight machine shop is di3ided into following sections. ! TTINE *%!TI"N T $NINE *%!TI"N A T" AND 'I*!%99AN%" * T""9 $""' 8$"D !TI"N 89ANINE AND T""9INE ,88T0 .AR CUTIN* SECTION:+ The bar cutting section deals with cutting .facing and centering of the bars and pallets to desired diameter and thic:ness with the help of different machines the different machines in bar cutting section are.
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1. B%ND *A=. +. !I$! 9%$ *A= 2. 8"=%$ 7A!&*A= 6. !"9 'N D$I99 -. 'I99INE 'A!7IN% In these machines, bend saw is more accurate and efficient machine and also the only one fully automatic saw. The circular saws are capable of cutting the bars of diameter e3en more then +..B2..mm. after bar cutting facing and centering is done with the help of 3ertical .column drilling and milling machines. These bar and pallets are then transported to the turning section of the 9'* ,9ight 'achine shop0. TURNIN* SECTION:+ In this section the centered and faced material is sub4ected to 3arious turning operation to form 3arious gears and shafts. The operation underta:en here initially produce a gear and shaft blan:s which are then machined into their respecti3e forms according to their function. The series of operations performed in this section are as under; 1. E%A$ B9AN& #"$'ATI"N. +. E%A$ ! TTINE. 2. E%A$ *7AGINE. TOOL ROOM:+ Tool room is the one of sensiti3e machining area in the 9'*. It mainly deals with the production of JIE M#INT $%. It is well equipped with highly prOcised machines for instrument

+A

calibration and setting them to their best le3el of accuracy. The 3arious machines of the Tool room are as under; D" B9% !"9 'N JIE B"$INE 'I&$"'AT ,E%$'AN T%!7N"9"EF0. 7FD$"8TI! ,*=I** T%!7N""EF0. 'IT* IB*%I&I ,JA8AN%*% T%!7N"9"EF0.

S+56 STUDER CNC *RINDIN* MACHINE :+ The important aspect of all the machines in the tool room is their temperature sensiti3ity. Their optimum temperature is ++P! and their accuracy is ..+ micron for the operation they performes. PRODUCTION PLANNIN*N* AND TOOLIN* :+ This area of 9'* is well equipped with the machines that are used to build the cutting edge of the tools. The cutting tools are sub4ected to inspection to measure the inaccuracy in their geometry. The tools are then grinded on highly prOcised and properly inde)ed grinding machines to obtain their cutting edges. This machining operation requires s:ill as the o3erall quality of the component manufactured depends on the cutting tool used. The 88T section is well equipped with gauges, broaches, hobs, thread rolls, reamers, taps and sundary tools, turning and milling cutters, Eleason cutters.

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#ig B2

These abo3e are the raw material used for the ma:ing gears. These all are casted and forged in forging section. #orging is done so that material cost is to be maintained as well as machining cost also.

MACHINES IN THIS SECTION

A T" #AF;B It is a special purpose lathe designed by Jones and 9ampson of America. !"8FINE 9AT7%;B It is used for copy turning of long shafts. A cutting tool mo3ing hydraulically generated the profile of same shape as that of masterpiece. 'ain features of this lathe are; (i) (ii) Automatic multi cycle copying 'a)imum performance and minimum maintenance

THREAD ROLLIN* MACHINE:+ It is a machine ha3ing two master rollers on which threads are present. Both rollers are mo3ing in cloc:wise direction. Job is inserted between two rollers for cutting of threads. There is a fi)ed time period for the roller for operator can fi) the thread
2.

cutting. In the bac: these threads are attached with the "ldham?s couplings for lateral misalignment.

HO..IN*: + It is done on single purpose hobbing m/c. *o far as design is concerned there are two basic types i.e. 7+ wor: spindle and Gertical wor: spindles. The Gertical type is more widely used. 'ultiple spindle m/c is used when production requirements are high. The 4ob spindle has two ad4ustments 1st the tool head is mounted on a swi3el base so that the a)is of the hob spindle may be set at an angle to a)is of the wor: spindle. The angle depend upon the heli) angle of the :ind of gear being cut and second, the hob spindle may be ad4usted a)ially as a means of distributing wear on the tools.

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21

These are some picture of component which are being made there.

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MACHINE SHOP
It is a part of tractor di3ision in which two types of hea3y casting ,Eear bo) and 'T housing0 are machined and some other components are also manufactured. In this shop the machines are arranged according to the sequence of operation and 4ob mo3es from one machine to another in series. This type of layout results in lerrer amount 'aterial 7andling. The machines used basically are special purpose machines ,*8'0 which are manufactured and for a particular operation. The 3arious types of machines present in this shop are; *emiBAutomatic 'achines;B $adial Drilling 'achine. 7ori5ontal 'illing 'achine. Gertical 'illing 'achine. Boring 'achine. Inclined Boring 'achine. Dual 'illing 'achine. Turret 9athe 'achine. Two =ay 'ultiple Drilling 'achine. Thread 'illing 'achine. !ylindrical Erinding 'achines. !omputer Numerical !ontrol ,!N!0;B 7ori5ontal 'illing !entre -...
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 7ori5ontal 'illing !entre <2..

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*EAR.O/:+ Eearbo) is that part of tractor which is mounted in the tractor between the %ngine and 'ain Transmission 7ousing. Its main moti3e is to transmit the power from the engine to rear wheels with reducing and increasing amount of *peed and Torque of the Tractor as per its operating load condition. The type of Eearbo) used in the tractor is *9IDINE '%*7 E%A$ B"N. In the Eearbo) the 8ower comes from engine to the clutch shaft and hence to the clutch gear which is always in mesh with a gear on the lay shaft. All the gears on the lay shaft are fi)ed to it and as such all the time rotating when the engine is running and clutch is engaged. The gears present on the splined shaft are free to slide on it. #ollowing are the main components of gearbo); B ,a0 Input shaft assembly. ,c0 9ay shaft assembly. assembly. ,e0 !lutch Actuator guide ass. ,g0 Eear bo) housing. ,I0 *hifter for: ,f0 Eears. ,h0 *hifter rods. ,40 Bearings. ,b0 "utput shaft assembly. ,d0 Intermediate shaft

,:0 #asteners, gas:ets and spacers. These gears are arranged in such a manner that when they mesh with 3arious other gears they gi3e different amount of *peed and Torque. These assemblies of gears and shafts are
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mounted on the gearbo) casting with the bearing, so that all the thrust of the gearbo) comes on the casting and the casting of the gearbo) remains strong and can ta:e all of the load and thrust of the fear without any distortion. After the manufacturing of the casting of gearbo) comes in 7'* shop for the machining operations, 7ere many operations li:e Drilling, Eroo3ing, 'illing, #acing and many other operations are done on the gearbo).

#ig B-

The 3arious operations carried out on the E%A$B"N 7ousing as it flows through the production line are;B a0 'ar:ing. b0 #ace 'illing. c0 Drilling. d0 #ace 'illing. e0 Boring. i0 Tapping. 40 #itting. :0 =ashing. l0 Erinding m0 Inspection
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f0 Drilling. g0 Drilling. h0 #inish Boring. MAIN TRANSMISSION HOUSIN*:+ The main transmission housing accommodates the differential which transmitt the power coming from the gearbo) to the half a)les and further on the rear wheels. =hen the tractor is tac:ing a turn the outer wheel will ha3e to tra3el greater distance as compared to the inner wheel at the same time. Therefore if the Tractor has a solid rear a)le only and no other de3ice will be tendency for the wheel to s:id. 7ence if the wheel s:idding is to be a3oided some mechanisms must be incorporated in the rear a)le, which should reduce the speed of the inner wheel, and increase the speed of the outer wheel when ta:ing a turn, the de3ice which ser3es the abo3e function is termed as differential. The 3arious operations carried out on the 'T 7ousing as it flows through the production line; a7 Mar1in!:+ #irst of all the ma:ing of reference line with respecti3e to the bores on the'T 7ousing !asing is done before the machining operation. It ta:es place on the surface table. The 'T 7ousing is mar:ed for the identification M 3isuali5ing of the machining depth and the right position of the bores and drills on e3ery si) sides of the 'T 7ousing.

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$7 Face Millin!:+ 'illing of the top and bottom face is done on the Duple) 'illing 'achine. The diameter of the face cutter is almost equal to the width of the area of wor:piece to be machined. c7 Drillin!:+ The Drilling of the + location holes on the bottom face of the 'T 7ousing is done on the radial drilling machine. The location holes are drilled in order to clamp the wor:piece on the fi)ture and also acts as reference holes for the other dimensions. d7 Face Millin!:+ The 'illing of the left and right face of the 'T 7ousing is done on the Duple) 'illing machine. "n this machines where are two spindles and the machining of the both faces is done correspondingly. e7 Face Millin!:+ The 'T 7ousing is clamped on the bed with help of the location holes and the face milling of the front and rear face is done. f7 .orin! :B The boring operation is carried out on the left and right side of the 'T 7ousing. !7 Drillin! :+The drilling operation is carried on the front and rear sides of the 'T7ousing. The operation is carried out on Two =ay 'ultiple Drilling machine. %ach spindles of 3arious drills rotates with 3arying speeds. 7 Tappin! :+Tapping of the holes is done on the $adial drilling machine with the use of tapping tool.

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i7 8a# in! :+The cleaning of the wor:piece is done by using hot water,heated at <.P!0 and casting soda to remo3e oilness and chips. 97 *rindin! :+The internal grinding is carried out as the last machining operation. 17 In#pection:+At last the inspection is done. "ther components manufactured in 7'* area; A0 *teering shaft bush B0 9eft hand shaft bush !0 Brea: Drum D0 Brea: Drum !o3er %0 #ront wheel hub HORI:ONTAL MACHININ* CENTRE ;HMC7+<66:+ 7'!B-.. is a fully automatic !N! hori5ontal machining centre with three linear a)is , $otary pallet inde) base, twin pallet changer and tool changing capability. This machining centre has been designed to automatically change tools for 'illing, Drilling , Tapping , Boring , $eamingBin fact perform most type of machining operations all in one handling of the wor: piece . nder the guidance of the !N! the tool is positioned at any desired point or it is made to follow any contour for the machining operations. Twin pallet changer automatically changes the required pallet on the pallet inde) base. MACHINE STRUCTURALS:+

2D

The entire main machine structural?s elements li:e Bed , *addle !olumn , 7ead, and pallet changer are built out of closed grain cast iron e)cept the pallet inde) base and pallet changer slide which are made of welded steel structures. 8a' $earin! arran!e"ent:+ The entire three liner a)es are ha3ing linear recirculation motion bearing system which has a 3ery low coefficient of friction. Their use eliminates stic:Bslip motion and thermal generation a high speed positioning. The saddle mo3ement o3er the bed pro3ides NBa)is motion, column mo3ement o3er saddle pro3ides C a)is motion , and head mo3ement o3er column pro3ides FBa)is motion . FEED dri3e#:+ *lides are dri3en by independent A!Bser3o motors enabling high acceleration deceleration and accurate contouring with infinitely 3ariable feed rates .to cut down idle time during positioning a rapid tra3erse rate of +.m/min has been pro3ided. 'otors are directly coupled to ball screws through torsion ally stiff coupling in all three a)es. Ball screws are mounted on stiff e)tra precision angular contact preloaded bearings. The position feed bac: is pro3ided through encoders in built into the motor resolution in stiff closed loop ser3o system. SPINDLE It carries ead:+ spindle assembly, timing belt and pulley

arrangement , power draw bolts and spindle orientation mechanism spindle motor hori5ontally mounted at the rear of the head pro3ides power to spindle a resol3er is fitted at the
6.

rare of the motor to pro3ide analogue speed feedbac: signal to the control system . the dri3e is equipped with thermal o3er load circuit to perfect motor and dri3e. AUTO TOOL CHAN*ER:+ 'achine is equipped with hydraulically operated double ended tool changing arm. Tool selection is random and biBdirectional through coded poc:et system. Tool maga5ine is standalone unit mounted on the left side of the bed. *tandard maga5ine carries 2+ tool poc:ets.

61

CHAPTER -3 ENGINE SHOP

6+

EN*INE SHOP
In engine shop there are manufacturing of the entire component which is being used in engine assembly. =e ha3e seen all the machining process which are used to made a particular component for e)ample connecting rod it ta:es 1different machines to be fully completed.

Fi!ure = This is the first state after casting in this picture 1 only facing is being done. #acing is done thrice time to fully complete the connecting rod.

62

Fi!ure > Abo3e figure is of hori5ontal milling machine which is used to cut the connecting rod to two basic hal3es one is the main connecting rod and another is the clamp which clamp the connecting rod into cran: shaft in cran: case.

Fi!ure ? This is the intermediate step for connecting rod after cutting to two hal3es. Below is the second part that is clamp.

66

Fi!ure @ In this shop we ha3e also studied about rear and front a)le, roc:er arm cran: case. In short in engine shop we ha3e studied the entire components which are used to complete the engine.

EN*INE SHOP
In new engine shop two main type of part of tractor engine are made one is cran: case of two cylinders, three cylinders, four cylinder and second one is cylinder head.

#ig B1.

6-

This is the bottom face of cran: case which is faced by using special purpose milling machine. The process which are being used for machining is 1. 'ar:ing B below is the fi)ture of mar:ing of three cylinder engine cran: case

Fi! +,,

10 The second process is facing of one side by putting in fi)ture made on *8' +0 Then ta:ing reference we drill two guide whole, with the help of this guide whole all the faces are finished by *8' machines.

6<

#ig B1+

Then all the required whole are drill by drilling machines. +nd is the cylinder head Below is the first stage of cylinder head after casting

Fi! +,4

10 #irstly we ha3e faced the one face after mar:ing and put into the fi)ture. As *hown in the figure.

6@

#ig 16

+0 Now with reference of this first face we operate all the ne)t step that are facing of all the si) faces. 20 Then drilling is done. 60 Al last inspection is done on marble which has high accuracy of flatness to gi3e correct testing.

6A

CHAPTER -4 ENGINE ASSEMBLY & TESTING

6D

EN*INE ASSEM.LPROCEDURE OF EN*INE ASSEM.L10 =ash the bloc: gently there should be no dust or dust particles. +0 !hec: all the holes and drillings and confirm that the bloc: is ha3ing accurate, measurements. 20 #it the bloc: tightly and chec: all the fittings.

-.

#ig B 1-

CRAN) SHAFT ASSEM.L-:+ 10 +0 'ain bearing fitment;B#or the proper lubrication of cran:. !ran: shaft fitment;B#or the proper fitment of seal.

-1

20 60 -0

$eal oil seal fitment;B#or the proper fitment of seal. "il 8ump fitment; B #or the proper fitment only. 'ain oil seal run out; B #or the ensure the centrali5ation of main oil seal.

#ig B1<

PISTON ASSEM.L-:+ 10 #itment of rings, %nsure the open end of the two nearest rings at 1A. deg M chec: ring clearance in piston groo3e. +0 $ing end gap; #irst ring ,..2< to ..-<mm0 ; *econd ring ,..+A to ..62mm0 ;Third ring,..2< to ..6Amm0 20 #itment of connecting rod. 60 %nsure fitment of big end bearing in the connecting rod. -0 !hec: connecting rod float.

-+

<0 %nsure matching of connecting rod notch to connecting rod cap notch. @0 %nsure piston arrow mar: should be front co3er side.

#ig B1@

TIMIN* *EAR ACASE ASSEM.L-:+ 10 Adopter fitment in #I8;B#or fitment of #I8 gear into #I8. +0 !am shaft gear fitment; B #or the 3al3e opening and closing at the right time. 20 #I8 fitment in the timing case;B#or the proper fitment of #I8 at the right position. 60 Idle gear 7 B fitment;B#or the matching idle gear 7 B hole. -0 Timing case fitment;BTo ma:e lea: proof to the 4oint of bloc:. <0 Idle gear fitment;B#or the right time of in4ection 3al3e.

-2

#ig B1A

TIMIN* CO0ER ASSEM.L-:+ 10 #itment of #I8 co3ers plate in the timing co3er with 1.- :g torque. +0 #itment of cam shaft stopper strip in the timing co3er. 20 #itment of bottom co3er with +.- :g torque. 60 8ress oil seal in the timing co3er bore. -0 #itment of cran: pulley. <0 %nsure the mar:ing of pulley with ,. deg0 when piston is at TD!.

#ig B1D
-6

LU.RICATION OIL SUMP ASSEM.L-;B 10 !hec: filter adopter properly M then fitments of oil filter body. +0 #itment of oil sump gas:et M used sealant of all matching faces. 20 !hec: oil sump fouling with main bearing cap. 60 %nsure inspection plug fitment in oil sump. -0 %nsure the fitment of drain plug. <0 #itment of dipstic: tube with tool M insert dipstic: gauge into dipstic: tube.

C-LINDER HEAD SU. ASSEM.L-:+ 10 9apping all 3al3e seat of cylinder head. +0 !lean the cylinder head with diesel. 20 #itment of thermostat hsg. 60 #itment of e)haust manifolds. -0 %nsure the fitment of engine lifting eye. <0 %nsure the freely mo3ement of tappet. @0 #itment of in4ector with the in4ector support with 1.- :g torque. A0 %nsure o3er flow pipe fitment with in4ectors. D0 %nsure fitment of high pressure pipe with clamp. 1.0 #itment of roc:er arm assembly. 110 %nsure tappet clearance. 1+0 Tappet co3er fitment with gas:et.
--

120 8ipe fitment for the lubrication of roc:er arm with adopter. 160 #itment of tappet co3er with breather pipe and gas:et.

EN*INE TESTIN*
After assembly engine is brought to engine testing section. In this section practical chec:ing of engine is done on engine and water supply is connected to it then the engine is started with the e)ternal Dc supply. There the proper operating of 3al3es is done, the engine is :ept running for two hrs. During running the load is also 3aried and 3arious properties li:e lubricating oil pressure, load capacity, fuel consumption etc is chec:ed. The lubricating oil pressure in the engine should be 2.A to 6.+ :g/cm+. #or proper wor:ing load capacity of engine is chec:ed by applying load on the shaft of the engine through water. Bra:e dynamometer in which water is applied on the roller when is turn pressure of shaft water. 8ressure is controlled by
-<

le3er. The load is applied in such a way that the ma) rpm of engine co3er down by +... The ma) $8' of engine shaft is :ept ++...

Fi! +26

*upplying a measured quantity of fuel usually also chec:s the fuel consumption of the engine 1..cc ,m20 of diesel or fuel is supplied to the engine. The time ta:en by the engine to consume the fuel is noted. During this testing, the engine is :ept on load.

FOR TESTIN* EN*INE IS )EPT RUNNIN* FOR ,HOUR AND << MINUTE

-@

CHAPTER -5 ASSEMBLY SHOP

-A

ASSEM.L- SHOP
Assembly shop is di3ided into two areas; B ,7 .efore Paint Area: + This consists of following subB assemblies. *ear .oB Su$+A##e"$l' :+ Dri3e *haft and Input shaft assembly. INPUT SHAFT ASSEM.L-:+ Input shaft consists of spiral gear on one end and splines on the other end. *plined part is attached to clutch and geared part ,QB1D0 is attached the constant mesh gear of lay shaft i.e. QB6-. Input shaft is put in to the gearbo) with the bearing, which is loc:ed by circlip. MAIN SHAFT ASSEM.L-: + 'ain shaft assembly is solid shaft with splines on outer surface. The shaft is placed in to gearbo) with both ends supported by bearings and loc:ed by circlip. The bac: part of shaft is pro4ected out side the gearbo) to get dri3e from it. The assembly of shaft !onsists of gears +6, 21 and 26 gear. The sliding gear 26 is used for first and re3erse gear, sliding gear 21 is used for second gear and sliding gear +6 for third and forth gear. These gears are pro3ided with groo3es on one side to attach gear shifter for:. Intermediate *haft assembly. "utput *haft assembly.
-D

 9ay *haft and !onnecting *haft assembly ,along with 8ower Transmission Eears0 LA- SHAFT ASSEM.L-:+ The lay shaft is hollow shaft with splines on outer surface. The one end of the lay shaft is threaded ,in case of single clutch0 and tightened from front side of gearbo) with a he)agonal nut. The whole assembly consists of gear QB6- i.e. constant mesh gear with input shaft gear0 spacer 1-mm, gear QB2-, gear QB+D, spacer 2.mm, gear QB+A, spacer +-mm and bearing with circlip. The whole assy. is washed. In case of dual clutch tractor model the dri3e shaft is placed through the hollow lay shaft. The dri3e shaft consists of splines on one end and a gear ,QB-+0 on the other end. The gear constantly meshed with the gear of intermediate shaft. The main function of lay shaft is to rotate fi)ed gear on it from where we can get different speeds with the help of sliding gear on dri3e shaft. *hifter $ods assembly ,along with *hifter #or:s0 !lutch Actuator *haft assembly. *teering assembly; BThis sub assembly comprises of 7igh and 9ow 9e3er, *hifter 9e3er and *hifter 7ousing. FRONT A/LE:+ #ront a)le of a tractor is a rigid tubular or I section steel construction, pi3oted at the centre. The pi3ot pin is housed on bushing on a support bolted to the front of the engine. As the trac: width of a tractor is ad4ustable, the front a)les ha3e pro3isions to be e)tended on both sides. The tubular front a)les ha3e telescopic arrangement for e)tensionK whereas IB section
<.

type front a)les are three piece a)les. Two side pieces are bolted to the middle piece with the help of two bolts through a set of holes, to get desired trac: width both the outer ends of the a)le ha3e pro3ision for holding :ing pin. These :ing pins are supported in the a)le housing with the help of metallic or nylon bushes. A thrust bearing is normally placed on the lower side of the :ing pin.

<1

STEERIN* *EOMETR-:+ Garious angles in steering geometry are ,( ca#ter an!le 2( c a"$er an!le 4( 1in! pin inclination an!le 5( toe+ in <( toe+out Ca#ter an!le:+ It is the tilt, i.e. The inclination of the top a)le or :ing pin towards the front or rear of the tractor. If tilted towards the front, it is positi3e caster M if tilted towards bac: it is negati3e caster. The purpose of caster is to gi3e a trailing effect to the front wheels. Ca"$er an!le: + It is a outward or inward tilt of the wheel at the top. If tilted outward it is positi3e camber M if inward It is negati3e camber. The main purpose of the camber is to bring the road contact of the wheel more nearly under the point of the load M to throw the weight on the inner wheels bearings which are larger than the outer )in! pin inclination an!le: + The :ing pin is tilted in at the top towards the 3ehicle in order that the weight of the load will be thrown towards the tyrecentre. The angle b/w the 3ehicle line M the :ing pin centre line is :nown as :ing pin inclination angle. Toe+in: +

<+

The wheels are closer together at the front than are at the bac:. The purpose of toeBin is to offset the camber M pre3ent e)cessi3e tyre wear.

<2

Toe+out: + ToeBout is the spreading apart of the front wheels on turns. The purpose of toeBout is to gi3e correct turning alignment M to pre3ent e)cessi3e tyre wear. STU. A/LE ASS-:+ Insert the cups of bearings to a)le hub by using hydraulic press. Attach the grease nipple to the a)le hub. Insert the si) bolts of wheel into the a)le hub. Ta:e a :ing pin stub a)le M put it on the special fi)ture. $emo3e the nut on the stub a)le side, insert felt ring on the stub a)le. Insert the wear ring on the :ing pin stub a)le. Insert the bearing on to stub a)le. Insert the a)le hub assy. Attach another taper roller bearing on it. Insert the washer on the a)le. Torque the castle nut on the stub a)le assy. with a torque of 6. pounds so that the bearings may occupy their original position. Now remo3e the castle nut M then again torque it with 1< pounds M loc: the castle nut with split pin. 8ut the co3er on it along the gas:et with the help of three screws and washers. #ill the grease through grease point and co3er it with grease nipple. Insert the oBring holder into the stub a)le. Insert the oB ring on to the oBring holder. Insert the thrust bearing on to the stub a)le. Insert felt ring on the stub a)le assy. FRONT A/LE ASSEM.L-: + Ta:e the bonnet basement and the front a)le brac:et M Join the front a)le brac:et with bonnet basement with four bolts and
<6

washers. 'ount the front a)le beam on the brac:et assy. Insert the rubber boot on the front a)le brac:et assy. Attach two grease nipples on the front a)le beam. Attach the front a)le beam on the brac:et with the help of pi3ot pin and two washers. 9oc: the pi3ot pin and on brac:et with nut, bolt and washer. Insert the stub a)le on both sides of the front a)le beam. Insert the felt ring on the stub a)le. Insert the *teering arm left into the beam, insert the woodruff :ey and loc: the arm with the help of screw, washer and nut. Insert the *teering arm $ight into the beam, insert the woodruff :ey and loc: the arm with the help of screw, washer and nut. Attach one grease pipe with washer on the a)le beam and fill it with grease and co3er the pipe with grease nipple. Differential Su$+A##e"$l':+

CASING C

SHAFT A SHAFT S2

SHAFT S1 PLANET GEAR (P)

SUN GEAR (G2) SUN GEAR (G1)

<-

It is rear part of the tractor cheesy. The main function of differential in tractor to reduce the final speed and also to turn the dri3e round at D. degree. The reduction of speed is done in two stages. #irst stage reduction in tail pinion and crown wheel meshing and second stage reduction in bull gear meshing with left and rights B.8.shaft. It?s also consisting the 8.T.". shaft ,8ower ta:e off shaft0, which is used to run the thrashers, pumps and other accessory components with the help of pulley attached on it. Follo%in! are "ain part# of differential 1. !rown wheel. +. Tail pinion. 2. !age assembly. ,=ith sun, planet gears and cross0 6. 8.T.". shaft.. -. Bull gears. <. Be3el gears. @. Bearings. A. Bearing cones. D. Bra:es housing assembly ,with disc and etc0. ASSEM.L- OF CASE CRO8N 8HEEL: + #irst of all components are washed with oil to remo3e the dirty particles. !age ha3ing two dowel holes in these holes dowels are tightening fitted for accurate fitting of crown so that all other holes of cage and crown come into same line. The crown wheel is pressed on case with hydraulic press and then tightens by bolts with loc: washer. Then right be3el gear is placed on their cage seat. The four pleat gears are put on cross with
<<

ou#in!: +

washer and then this assembly put on their placed on cage. Then placed left be3el gear on planet on gear. "perator to chec: the motion of gears does manual inspection. !age left is placed on left side of right cage assembly and then tighten by bolts and washer. TAIL PINION ASSEM.L-: + #irst of all in T.8. assembly the cone for taper roller bearing is pressed with hydraulic press. The bearing is heated before the tight fit. Then tail pinion is inserted inside bearing. The diff. si5e shiarealso placed before the tighten of rear co3er of cage. =hole assembly is tightening by nuts and bolts.

#ig B++

REAR A/LE ASSEM.L-:+

<@

In rear a)le assembly of tractor the bolts are tight fitted in holes of hub. =here the rear tire is tighten with their bolts to whole assembly. #or tight fitting the hydraulic press is used and 1+.B:gRcm sq. forces is apply. Two bearing either side of trumpet housing are tighten at their respecti3e place of cone. The rear a)le is passed through these two bearing with seal in trumpet. The co3e is used to co3er the open side of trumpet housing ,hub side0. The inner side bearing is lubricated with oil and outer bearing is lubricated with grease. .RA)IN* ASSEM.L-: + This tractor ha3ing hea3y duty *elfBenergi5ing, water sealed disc with spherical roller and 3entilation pipe which gi3es better cooling. The 3entilated results in reduction of about 2.L in pad temperature. Bra:e housing co3er contain two disc made of asbestos base nonBmetallic. The ma). Temp. $esistance about 2.. degree ! bRw these two disc plate a cast iron plate is fi)ed which contain steel spherical roller and hold by spring. =hen e3er bra:e is applied the spherical roller mo3e or lift from there place in the plate and try to e)panded the plate. During e)panding of !.I. plate the disc are strongly mounted on B.8.left and B.8. right shaft to stop the speed of differential. It also ha3ing actuators and lin: with rubber seal. P(T(O( SHAFT ASSEM.L-: + Two bearings are tightly fit on 8.T.".shaft at their proper placed with help of circlip loc:, which pro3ided on both side of bearing first of all the 8.T.". shaft assembly is pass through rear 8.T.". hole of differential housing. Then two cones are one on B.8. left
<A

and other on B.8. right shafts hole side inserted tightly. The B.8. left and right shaft assembly is placed through their hole then cage housing of differential is placed bRw left anted right B.8. shaft. The seal carrier with different si5e of shims is tightening by bolts on both side of differential housing ,right and left B.8. shaft side0. Then pre loading test is done with 1. :g force to rotate the cage assembly. If pre load force is increase the efficiency of taper bearing is decrease due to o3er friction bRw cage of bearing if decrease pre load force then the efficiency of taper bearing also decrease due to less contact with co3er cage of bearing. Then tail pinion assembly is inserted in to respecti3e hole with shims and tail pinion teethes meshed with crown wheel teethes. #ollowing three testing is done; B 1. Bac: lash testing. +. LAge of contact M 8attern test 2(,(<(, .AC) LASH TESTIN*: + This test is performed with help of plunger dial gauge. Bac:lash in crown wheel is not more then +. to 2. micron if it is de3iated from this 3alue then pac:ing is change on either side ,left or side0 of cage of bearing housing. But ne3er change the number of shim. If bac:lash is more then 2. micron then shims from right side is remo3ed and shifted in to left side. If it is less then +. micron then 3ice 3ersa. 2(,(<(2 CA*E OF CONTACT TEST AND PATTERN TEST:+ 8attern test and Lage contact test is done with help of yellow paint apply on teethes of crown wheel. Then rotating crown
<D

wheel with hand Lage contact and pattern of tail pinion is impressed on the teeth of wheel. The Lage of contact is <.L to @.L required. It can be increase or decrease by using the shims by fastening it on tail pinion carrier. =hen increase in number of shims the pattern goes increase and 3ice 3ersa. T.8. pre load !.=. pre load !.=. run out B.9. A :gf 1+ :gf ..-B.1 mm .+B.2 mm

The bull gear are tighten to trumpet housing assembly by loc: nut and the whole assembly of trumpet housing is also tighten by nuts on studs and on outer side of differential housing Then 8.T.".shaft head co3er is tighten on 8.T.". shaft to protect the outer teeth. The sliding gear and 8.T.". shifter rod assembly is mounted on differential housing. Two filters are placed inside of diff. housing and then whole assembly of diff. housing is sending to the main line. Rear ABle a##e"$l':+ The parts of rear a)le assembly are with trumpet housing on which wheels are mounted on either side of a)le tube and bull gear. The function of differential assembly is to bring about a change in the speed of engine during turning, while turning sub assembly of cross and star gear pro3ide less speed to inner tires and more speed to outer tires thus pre3enting the o3er turning of machine.

@.

T e *ear .oB i# t en a##e"$led %it t e Differential in t e fir#t loop( T e *ear .oB i# $rou! t to t e loop t rou! t e con3e'or $elt( Rear Co3er Su$+A##e"$l':+ !ontrol *ector assembly,8osition le3er and Draft le3er assembly0 !ontrol Gal3e assembly ,$elie3e 3al3e and $esponse 3al3e0. $am assembly; This assembly consists of cylinder, piston and piston rod. The piston rod is connected to operating cylinder that is used for lifting purposes. Rear Co3er i# t en a##e"$led to Differential+ *ear .oB #u$+a##e"$l' t rou! con3e'or $elt( ACUTATOR ;C(A(7 *UIDE: CLUTCH:+ !.A Euide is the assembly in which the bearing is tightens, fitted and loc:ed with circlip. Inner bush is placed and hold it with !.A. guider springs. The main function of the !.A guide is to push the release le3ers ,fingers0 so that the clutch is operated easily. INTERNAL *EAR ASSEM.L-:+ "n internal gear two dowels are inserted at their proper place and faceplate with thrust plate is placed o3er dowels. The purpose of the dowels is to locate holes on the plate w.r.t internal gear. The planet carrier contains three planet gears, which are fi)ed to carrier with help of pins inserted through them. The planet gear and carrier assembly is placed inside the internal gear then thrust plate and outer plate is placed and tightened by nuts. ASSEM.L- OF *EAR .O/:+
@1

#irstly, clean the gear bo) housing and load it on the wor:ing trolley. #it the bearing Mcir clip in the casting. #it the idler cluster with the idler cluster shaft. #it the input shaft to the gear bo) housing M loc: it with cir clip. #i) the lay shaft M loc: it with chec: nut M torque it. #it the intermediate shaft. #i) the shifter rod M shifter for:s. #it the planet carrier assy. to the gear bo) M insert the output shaft in it. Attach the hiBlow shifter for: to the hiBlow slee3e. #it the inner bush, !.A guide, !.A shaft M !.A for:. #it the Q.# steering assy. to the Q.#. mounting brac:et. Attach gear shifter housing to the gear bo). !hec: all the gears engagement. Then unload the gear bo) from the line with the help of %.".T crane. REAR CO0ER ASSEM.L-:+ $ear co3er assembly is used to co3er the differential housing. It contains lift control system, which is hydraulically operated. Dri3er seat is fitted on the upper side of rear co3er. The response 3al3e housing ,$.G.0 control 3al3e, cylinder and other components assembly fitted inner and outer side of rear co3er assembly. The main components are fitted in rear co3er assembly ,a0 !ontrol 3al3e assembly. assembly. ,c0 $am cylinder and piston assembly with ram arm. ,d0 !ontrol sector assembly. assembly. ,f0 Eas:ets, bolts, nuts. RAM C-LINDER ASSEM.L-:+
@+

,b0 $.G. housing

,e0 *ensor

tube

,g0 !oupler assy.

It contains piston inserted inside the cylinder. The relief 3al3e assembly is mounted at top front of cylinder. The connecting rod is placed in piston rear side and one side is loc:ed with ram arm assembly .Then roc: arm, spacer and seals

SENSOR TUBE.

COUPLER ASSY . RAM CYLINDER.

#igB+2

are placed. At the end of roc: arm assembly lift arms are placed and then loc:ed with bolts on both side. The operating pressure for relief 3al3e is +.-B+1. :g/cm sq. CONTROL SECTOR ASSEM.L-:+ It contains the draft cran: assembly, which is placed through the hollow position cran: assembly. Both these assembly are connected to their le3er. The position cran: assembly is connected to blac: mar: le3er and draft cran: assembly is connected to red mar: le3er. All assembly is fastened with bolts, nuts, washer and loc:nuts.
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COUPLER ASSEM.L-:+ In coupler assembly a draft rod ha3ing a coupler for sensing action and spring .8osition rod contains spring on it. Draft rod assembly is connected to the draft le3er and position rod to position le3er through the spool 3al3e. =hole assembly is fitted inside rear co3er. REAR CO0ER ASSEM.L-:+ #irst of all clean the casting and load it on the wor:ing trolley. #it the sensor bush to the sensor hole. #it the stud on the rear end. #i) the breather bolt M cap it with breather cap. Turn the rear co3er down to 1A. degree. 8lace the gas:et on the position draft section on assembly section. Bolt the coupler connection bush with the rear co3er. 8lace the ram arm on rear co3er housing. 8lace the roc: shaft in the ram arm assembly by light hammering. 8lace the spacers one by one with mandrel. #it the lift arm to the roc: shaft and bolt it with a retainer plate. 8lace the connecting shaft, ram arm inside the ram cylinder assembly. Bolt the ram cylinder assembly with the rear co3er. !ouple the for: on the coupler assy. to control 3al3e and bolt the $.G housing. Eauge the position off draft assy. with gauge of -2.- mm. loc: the coupler with loc: nut. Turn the rear co3er upward and attach the $.G housing. #i) the sensor tube on the stud and bolt it. 9ift the rear co3er and place on the testing bench 3ia %.".T crane. !hec: for proper wor:ing M ma)imum lift capacity of the lift. Then unloading the rear co3er from the testing bench with the help of crane.

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CLUTCH:+ The clutch wor:s on the principle of friction in which when one stationary surface is brought into contact with a rotating surface, the stationary surface also starts rotating. The main function of the clutch is to engage or disengage the power coming from the engine. "n the basis of wor:ing, there are two types of clutches;B 1. single clutch +. double clutch

,( Sin!le clutc :+ In this clutch, three fingers, also :nown as release le3ers, are centrally fulcrum to the clutch co3er with their outer ends connected to the pressure plate. A release bearing slightly away from the free ends of the fingers mo3es to M fro on the clutch shaft with the help of a for: which is connected to the clutch pedal through the lin:age. As soon as the pedal is depressed, the release bearing mo3es towards the flywheel M press the fingers. As the fingers are fulcrum at a point in their length to the clutch co3er and the other end is connected to the pressure plate, as soon as the free ends are pressed inside by the release bearing, the outer ends tend to bring the pressure plate away from the clutch plate against pressure springs, ma:ing the clutch plate and hence the clutch shaft to disengage, but the pressure plate and the co3er remain rotating along with the flywheel. 2( Dou$le clutc : +
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This clutch is pro3ided with two clutch plates one for the main transmission M the other for 8.T." dri3e. In b/w the two clutch plates, an intermediate plate is pro3ided. Normally, si) release le3ers ser3e the purpose of disengaging the clutch plates. "ut of si), three are for engine disengaging M the rest of three are for disengaging the 8.T.". dri3e.

Clutch plate

CLUTCH ASSEM.L-:+ #irstly, load the engine on trolley. !lean the flywheel properly with stone M cloth so that their must not be any dust particle on the face of the flywheel. Now, fit the clutch plate and pressure plate by using spanner. Torque the clutch assy. with the help of torque wrench. Now fit the front a)le assy. on to the front of the engine.

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4( After Paint Area: This area consists of the following subBassemblies. #ender $im Dash Tyres #ront *hield and 'as: #uel Tan: Erill #rame Air !leaner *ide 8anel *ilencer Top Bonnet *teering *eat Battery Paint S op:+ "perations performed in paint shop are; *urface 8reparation ,8re Treatment !ell0Bcarried out for sheets and rims. 8ainting Inspection $e4ection ,$eprocessing0Bfor sheets and rims. Pre+Treat"ent Cell:
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Board

Garious procedures followed here are; o Degreasing o =ater $insing ,part which is degreased is al:aline in nature so rinsed with water due to its being good sol3ent0. o De $usting o *urface o)idation o 8hosphating ,done so as to form a thin layer of coating on part so that no surface remains unpainted0. o 8assi3ation ,done so as to a3oid paint penetrating through certain section of part body?s surface0. Paintin!:+ C a##i# Paint Line:+ o =ashing; 7ere chassis is first washed with a chemical cleaner, concentration of which is -L and auto sprayed in a chamber. o Drying; The chassis is then dried by hot air whose temperature is up to <. to @.!. o 8rimer 8ainting; A thin layer of primer paint is sprayed on the chassis so that the final paint is strongly fi)ed on. o #lash "ff; This is the distance gi3en so as to allow paint to dry. o #inal 8ainting o Ba:ing; !hassis is allowed to ba:e for around 2. minutes.

S eet and ri"# Paintin!: +

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After surface preparation in 8T!, sheets and rims are first of all cleaned with ordinary cloth. Thereafter following operations are carried out; o 8rimer painting ,full primer in addition to single coating of paint0 o #lash off o Ba:ing ,at temperature of around 1+.B12.!0 o =et $ubbing and cleaning with tac: rag o #inal painting o #lash off o Ba:ing

ROAD TESTIN*:+ After the tractor being ta:en out from the assembly line after inspection, road testing is done. In road testing, the wor:ing of gears, bra:es M proper running of tractor is chec:ed. 7umming noise from the differential is also chec:ed by the operator. ROLLER TESTIN*:+ After road testing, $"99%$ testing is done. In this the wor:ing of hydraulic system M engine at full load is chec:ed M if it is "& then it is send to 8.D.I stage where hydraulic oil is filtered M toe in is ad4usted. But if it is not "& then it is send to minor rewor:.

PROCEDURE FOR ROLLER TESTIN*:+

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#ollowing are the points for $oller testing K ,(H'draulic#:+ a. $.G,bowling0 b. 9ower lin: play to be chec:ed ,ma).1I0

2( Lift 9er1in!& lift #tic1in! (

untin! &#lo% lift &#elf lift& lift

4( Lea1a!e of

'draulic# :+

a. Deli3ery pipe, suction pipe M ban4o bolt. b. $esponse 3al3e body. c. 7ydraulic pump adaptor.

5( Lea1a!e of en!ine oil :+ a. 8lug. b. "il sump. c. "utput ben4obolt , oil filter . d. "utput gauge adaptor(

<( Lea1a!e of fuel:+ a. #ilter. b. In4ector o3er flow plugben4o.

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c. Ben4obolt . d. #uel filter drain plug. e. 8ipe. f. #.I.8 pre fuel filter. g. #uel Tan: and drain plug.

=( Lea1a!e of %ater:+ a. =ater pump seal, water manifold. b. 7ose pipe, sensor plug.

>( Ot er Lea1a!e#:+ a. 8T" oil seal. b. Differential drain plug. c. "il filter. d. #lywheel housing 4oint.

?( S"o1e c ec1in! ;3i#uall'7(

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CHAPTER-6 QUALITY ASSURANCE

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DUALIT- ASSURANCE (uality assurance acti3ity in 7'T is an 'I* function to audit and report the quality status of both , products well as quality assurance systems within the plant considers the 3endors as an e)tension as its own manufacturing operations. 7ence the quality assurance audits are not limited to 4ust recie3ed components at 7'T receipt inspection stage but e)tends to audit of conformance to prescribed quality assurance systems at 3endor end also. O.EECTI0ES:+ ,. 2( To reduce re4ection and achie3e better quality standards. To achie3e consistency in quality.

(uality which has no compromise, is essential for e3ery industry to stay affirm in today?s competiti3e world. 'y pro4ect is a long term pro4ect for e3ery industry. %ach industry feels to upgrade its position and 3endors are integrated parts of it. (uality impro3ement at 3endor?s end means o3erall impro3ement in company?s gradation. =ith high quality from 3endor, ma4or goals of impro3ement can be achie3ed.

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CONCLUSION
=or:ing with IND" #A$' %( I8'%NT 9TD. as a summer training was a 3ery nice e)perience. I also practiced what I learnt in the uni3ersity and applied it on field. =or:ing with this automobile department enhanced my ma4or understanding. In addition, I gained a good e)perience in term of self confidence, real life wor:ing situation, interactions among people in the same field and wor:ing with others with different professional bac:ground. I had an interest in understanding basic engineering wor: and practicing what has been learnt in the class. Also, the training was an opportunity for me to increase my human relation both socially and professionally.

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TECHNICAL SPECIFICATIONS OF INDOFARM TRACTORS 46=< DI:+

78 $ANE% B"$% /*T$"&% TF8% N". "# !F9IND%$ $AT%D *8%%D !""9INE *F*T%' =7%%9 T$A!& D$IG%$ *%AT *T%%$INE .ra1e T'pe T$AN*'I**I"N N". "# E%A$ <1.+B11.mm DI%*%9, #" $ *T$"&% 6 ++.. $8' =AT%$ !""9%D 16+<B1D6.mm ADJ *TAB9% 8"=%$ AND '%!7ANI!A9 D$F AND =%T,"I90 A #"$=A$D AND + $%G%$*%

INDO FARM 46=< DI

6 !ylinder 8owerful %ngine A#S+$ *peed Transmission. 9ift !apacity 1A.. &gs at lower lin: ends 7igh #uel %fficiency
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7igh Torque Bac:up 8ower *teering and "il Immersed Bra:es *traight $ear A)le for %asy 'aintenance

INDO FARM 5,>< DI

D$IG% %NEIN% !9 T!7 8A$&INE B$A&% BATT%$TF =7%%9 T$A!& B$A&% INDO FARM 5,>< DI

+=D AND 6=D 6*T$"&% @-78 D" B9% !9 T!7 IND%8%ND%NT B$A&% 1+G"9T 16+<B1D6.mm =%T AND D$F

1+/1+ *peed !arraro Transmission. *ynchromesh Eear Bo) *ide *hifter Eear Independent Dual *peed 8T" -6./1... rpm 9ift !apacity +<.. &g 7igh #uel %fficiency

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REFERENCES
888(INDOFARM(IN COMPAN- PAMPHLETS Trul' #upported $' H(R depart"ent;indo far"7

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