ASHOKA

ASHOK IRON WORKS PVT LTD.
CHAPTER 1
INTRODUCTION TO COMPANY
1.1 Company profile

Ashok Iron works was founded in the year 1974. By Mr. Ashok S.Humbarnadi. It is
one of the leading Industries. Currently Ashok Iron Work Company holds the fourth place in
leading job foundries in India.
In fact AIW is one of the very few foundries which is QS-9000 certified. The company has
appointed a marketing consultant in Germany for developing new over customers.
Sector - Material
Industry - Iron and steel
Sub industry - Iron and Steel foundry
Area - 18600 (sq. metre.)
Man Power - 500 (one plant Jai Hind Eng.)
Total Plant - 14 (In Belgaum Only)
Chairman: Mr. Ashok S. Humbarnadi
Joint Managing Director: Mr. Jayant Humbarnadi
Director: Mr. V. S. Katkar
Address - Mazagaon Road, Udyambag,

Belgavi, Karnataka, India
590008.
Phone - 0831-2442599
Fax - 0831-2441899
Website - ashokiron.com
1.2 Main Features of Company-

 ISO-9000 company
 Implementation of Kaizen Principle
 Implementation of Poka Yoke
 Implementation of 5S tools
DEPARTMENT OF MECHANICAL ENGINEERING

KLE SOCIETY’S KLE COLLEGE OF ENGINEERING AND TECHNOLOGY, CHIKODI. Page 1
1.3 Customers
Plant: Ashok Iron Works Unit-III

 TAFE
1. Transmission Case
2. Centre Housing
 ESCORT
1. Axle Housing
2. Front Engine Support
 MAHINDRA & MAHINDRA

1. MMTC (Transmission Case)
2. VTU HSG (Hydraulic lift housing)
3. H2 CL HSG (Clutch housing)

1.4 Process Flow Diagram
CASTING FROM
FOUNDRY
VARIOUS MACHINING
OPERATIONS on
CRANKSHAFT
FINISHED PRODUCT
CLEANING AND
INSPECTION
DISPATCH

CHAPTER 2
MACHINING OPERATIONS
Below operation are given sequentially done on CRANKSHAFT (KV12/16) to
produce final product.
2.1 Operation No1: Connecting Pin Milling

 Machine Name: GFM MACHINE
 Machine type: Special Purpose Milling Machine
 Operation: Connecting Pin(cp) Milling
 Machine description:
 Cutting speed:250 rpm
 Feed:160mm/min
 Timing:
 Initial setting 5:05min
 Machining time: 62:12min
 Overall time: 67:17min
 Tool:
 Milling cutter with 60 inserts (Día. =68cm)
 Insert-
1.Radius inserts
2.Diameter inserts
3.Corner inserts
 Coolant:
 Cold air
 Super-90 oil
 Dimensional inspection:
 Initially check the degree &set it for zero using dial gauge.
 Check width of CP using width gauge.
 Check the throw using Throw gauge.
 Maintenance:
 Preventive maintenance: Every month.
 Breakdown cause: coolant hydraulic problem, CNC system problem chip conveyor
problem etc.
 Note:
 GFM machine gives the CUTTING PROFILE using which machining process can be
understood easily.
 If any problem get occurred while machining can understood using CUTTING PROFILE.

2.2 Operation No 2: Main Bearing Turning

 Machine name: J & L MACHINE (JONES & LAMSON)-2
 Machine type: Flange, SF Gear Hard Turning
 Operation: Main Bearing (MB) Turning
 Machining description:
 Speed: 150 rpm
 Feed: 100 mm/min
 Timing:
 Machining time: 4:35 min
 Machining time: 33 min
 Overall time: 37:35 min
 Tool:
 V- Tool, RH-TOOL, LH- TOOL
 Corner change: 240-250 jobs
 Tool change frequency: 960-1000 jobs
 Coolant:
 Super -90 oil
 Lubricant:
 Way-68
 Check the MB diameter before machining & after machining using DIAL SNAP
GAUGE.
 Check the width of the MB using WIDTH GAUGE.
 Maintenance:
 Preventive maintenance: every month
 Breakdown causes: motor problem, CNC problem, coolant & lubricant oil problems, etc.
 Note:
 Feeding is done automatically by CNC system as shown in the Fig.2.1
 Tool holder used to hold the V, RH, LH Tool which as operated as per the program given
to the CNC system.
 LH tool machines the left side of MB; RH tool machine the right side of the MB & V-
Tool machines the middle portion of the MB of a crankshaft.
 Magnetic conveyer system is used to carry out the chip.

Fig. 2.1: Main Bearing Turning.

2.3 Operation No 3: Oil Hole Drilling

 Machine Name: WIDMA GUN DRILLING MACHINE (Single spindle)
 Machine type: CNC Type
 Operation: Oil Hole Drilling
 Operation description:
Operation description of oil hole drilling is shown in the table 2.1

Table 2.1: Operation Description.
Operation Speed(rpm) Feed Time (Min) Material Tool change

(Diameter in (mm/min) freq. (jobs)
mm)
MB oil Hole 2000 300 3:17min Carbide 100-125
(7.94mm)
CP oil hole 2000 300 4min Carbide 100-25
(7,94mm)
 Timing:
 Machining time of MB Oil Hole: 19:42min
 Machining time of CP Oil Hole:48min
 Tool:
 Drill cutter: Diameter =7.94mm &length =415mm
 Bush is used to hold the Drill
 Coolant system:
 Coolant: MEHTOL NC14H
 Automatic cooling system
 Lubricant oil:
 Way 68
 Maintenance system:
 Preventive maintenance is dined as per the plan.
 Breakdown cause: coolant system problems, lubrication problems, electrical & hydraulic
problems, etc.
 Note:
 Automatic indexing is done to drill CP oil hole as per required angle &position (this is
done using CNC Probe) as shown in the fig 2.2.
 Hydraulic system helps to hold the work piece& in clamping.
 Magnetic chip conveyor is carrying all chip produced in this operation.
 Steady is used to support the rotating work piece.

Fig 2.2: Oil hole drilling.

2.4 Operation No 4: Counter Boring

 Machine name: RADIAL DRILLING MACHINE
 Machine type: Manual Drilling
 Operation: Counter Boring
 Machine description:
 Speed:100 rpm
 Timing:
 Counter bore tool
 Tool change frequency:900-1000 jobs
 Corner change frequency: 240-250 jobs
 Maintenance:
 Preventive maintenance as per the plant set.
 Breakdown causes: Clamping problems, electric motor problems, etc.

2.5 Operation No 5: Buffing of Oil Holes

 Operation Name: Buffing of Oil Holes
 Operation Name: Finishing of Oil Countered Oil Holes
 Tool: Buffer Tool
 In this operation finishing of counter bored oil holes is done.
 Emery polish paper attached at end of the tool & polishing is done.
 Buffer tool is rotated at high speed (about 200rpm) using high pressurized air.
 It is done by manually.
 Time:
 Buffing time of all oil holes: 7-8min
 Overall time: 7:34-8:34min
 Maintenance:
 Only breakdown maintenance.

2.6 Operation No 6: Induction Hardening

 Machine name: EMA INDUCTION HARDENING MACHINE
 Machine type: CNC
 Operation: Induction Hardening
 Purpose: To increase the life of the component
 Initially clean the work piece to remove oil content present on the work.
 Fit the induction coil of size of CP/MB.
 Heat the MB/CP to temperature of about half the melting of the material (for given
material heat to temperature of 800°𝑐) as shown in the fig.2.3
 Hold the job to same temperature or 6-7sec.
 Then quenching is done in C201POLYMER Oil for 30-32sec only.
 Maintain the concentration of quenching oil to 12±1 which can be measured by
instrument called Refractometer.
 Timing:
 Total time to heat all CP &MB:36sec
 Total quenching time:6min
 Induction coil:
 Voltage: 3*415V
 Frequency :50 Hz
 Power :62KVA
 Temperature :800°𝑐
 Quenching system:
 Quenching oil: C201 polymer oil
 Maintain the concentration of the oil to 12±1 which can be measured using
REFRACTOMETER.
 Quenching delay ; 30-32sec
 Maintenance:
 Preventive maintenance is done as per the plant set.
 Breakdown causes: electrical problem, induction coil problem.
 Note:
 Before heating the work, piece fill the oil holes with wooden plugs. To avoid the +
 destruction of oil holes.
 Using this operation life of the component can be increased & hardness can be increased
to 55-60%.
 Check the concentration for every shift by using the refract meter.
 This provides the fume extractor which extracts all fumes produced while heating &
quenching process.

Fig.2.3: Induction Hardening.

2.7 Operation No 7: Furnacing

 Operation name: Furnacing (Tempering)
 Purpose:
 To relieve residual stresses.
 To reduce bending occurred in the in-induction hardening operation.
 To increase the life of the component.
 Tempering description:
 Furnace temperature: 370°c
 Duration of temperature: 8 hours
 Using fans air is circulated.
 Timing:
 Tempering time: 8 hours
 Overall time: 8 hours
 Furnace details:
 Capacity furnace: 12 work pieces
 Fans provided at the top of the furnace for air circulation which are run by electric
motors.
 Coils are present at the sides of furnace using which heating has been done.
 Maintenance:
 Preventive maintenance is done as per the plan set.
 Breakdown causes: electrical problems, furnace problems, etc.
 Note:
 Using this process, the stresses are get relieved and life of the component also increases.
The loading of the crank shafts in the furnace is shown in the fig.2.4
 By the tempering process the hardness can increased by 45-50% only.
 Temperature of the furnace is maintained by controlling the voltage and current through
resistance coils.
 Tempering is also known as the air quenching process.
 After the operation check bend using dial gauge.

Fig. 2.4: Furnacing.

2.8 Operation No 8: Shot Blasting

 Operation name: Shot Blasting
 Machine name: SAND STORM MACHINE
 Purpose:
 To remove scales developed on surface of component.
 Shot blasting Description:
 Speed of work piece is about 35 to 40 rpm.
 Pressure of the steel balls hitting the component is about to be 90kg/cm².The shot blasting
chamber is shown in the fig. 2.5
 This hitting of steel balls is done for 15 to 20 minutes till the scale, dust etc are
completely removed from the work piece.
 Timing:
 Shot blasting time: 20min
 Overall operation time: 23:46 min
 Maintenance:
 Preventive maintenance is necessary to check only working blower and pressure of the
steel balls.
 Breakdown maintenance causes: electric motor problem, nozzle problems, etc.
 Precautions:
 Steel balls used should the diameter less than 2 to 3mm.
 Pressure should maintain to required level.
 After every 5 to 10 minutes check work surface (because due to high pressure balls the
surface of work and damage).
 Check the leakages in pipes for every operation.
 For every shift check nozzle hole (if necessary).

Fig.2.5: Shot blasting.

2.9 Operation No 9: MB Rough Grinding

 Operation name: MB rough grinding
 Machine name: MSO GRINDING MACHINE
 Speed of the grinder: 700 rpm
 Speed of the work piece :25 - 30rpm
 Feed: manually
 Cutting speed: 0.22m/min
 Tool:
 Material: ceramics
 Grinder diameter:
 Dresser used to sharpen the grinder
 Time:
 Machining time:
 Overall time:
 Coolant oil:
 Coolant oil:WS600(soap oil)
 Temperature of coolant oil: 18-20°c
 Check the oil concentration for every shift (i.e. to be about 12±1)
 Lubricant oil:
 Lube oil: Way-68
 Check the MB diameter by the dial snap gauge.
 Check width of the MB by width gauge.
 Check MB thrust radius by radius template.
 Check for the crack by crack test method.
 Maintenance:
 Preventive maintenance is done as per plan set.
 Breakdown causes: coolant oil problem, electric problem, feeding problem, etc.
 Note:
 Initially check bend in work using dial gauge.
 Before loading the work piece on machine apply grease at both end of work to avoid
friction.
 As the feeding is manual check the diameter of MB at every time using dial snap gauge.
 Before start of machining control, the radius at the corner of the grinder using MSO
dresser radius at corner should be as per the standard provided.

2.10 Operation No 10: CP Rough Grinding

 Operation name: CP rough grinding
 Machine name: TOSS GRINDING MACHINE
 Speed of the grinder: 650 rpm
 Speed of the work piece: 25-30rpm
 Cutting speed: 30-32mm/min
 Indexing required in this operation is done automatically by CNC system
 Tool:
 Grinder diameter: 1000mm
 Diamond dresser used to sharpen the grinder
 Time:
 Job/shift:7
 Coolant oil:
 Coolant oil: WS600(soap oil).
 Temperature of coolant oil: 18-20°c.
 Check the oil concentration for every shift.
 Coolant flow rate: 80-90lpm.
 Lubricant oil:
 Dimension inspections:
 Check the CP diameter by dial snap gauge.
 Check width of CP by width gauge.
 Check CP thrust radius by radius template.
 Check the throw using throw gauge.
 Maintenance:
 Breakdown causes: coolant oil problem, electric problem, feeding problem etc.
 Note:
 As per feeding is manual check the diameter of CP at every time using dial snap gauge.
 Before start of the machining control the radius at the grinder of the grinder. the process
is shown in the fig. 2.6

Fig. 2.6: CP Rough Grinding.

2.11 Operation No 11: FE & GE Turning & Groove Cutting

 Operation name: FE & GE Turning & Groove Cutting
 Machine name: J & L MACHINE (JONES &LAMPSON MACHINE)-01
The operation description of FE & GE turning & groove cutting is shown in table 2.2
Table 2.2: Operation description.
Operation Speed(rpm) Feed Time (min) Tool
(mm/min)
FE turning 700 2 6:34 LH/RH
GE turning 700 2 5:39 LH/RH
Groove cutting 700 2 11:22 V-Tool
 Timing:
 Machining time: 22:75 min
 Job/shift :7-8
 Tool:
 Left hand, right hand tool, V-tool
 Material: HSS
 Using V tool, the groove cutting is done
 Coolant oil:
 Coolant oil: WS600(soap oil)
 Temperature of coolant :18-20°c
 Check the oil concentration for every shift (i.e.to be about 12± 2)
 Coolant flow rate:80-90lpm
 Lubricant Oil:
 Check the GE & PE diameter by Dial snap gauge.
 Check big collar thickness using snap gauge (Go /NOGO gauge).
 Maintenance:
 Breakdown causes: coolant oil problem, electric problem, probing problems.
 Note:
 With the help PROBE system location of the groove & ZERO setting distance is set in the
CNC system.
 Diameter of the GROOVE can check by using C-Gauge.
 The cutting speed is on this machine is about to be 106.78mm/min.

2.12 Operation No 12: MB Finish Grinding

 Operation name: MB Finish Grinding
 Machine name: AMC-CNC-1 MACHINE
 Speed of the grinder: 800rpm
 Speed of the work piece: 25-30 rpm
 Use steady to support the work while machining.
 Before machining initially check the diameter of MB & set the program.
 Tool:
 Grinder diameter: 1000mm
 Diamond dresser used to sharpen the grinder (done automatically).
 Time:
 Job/shift:10
 Coolant oil:
 Coolant oil: Bio cool oil
 Temperature of coolant oil: 18 -20°c
 Check the oil concentration for every shift (i.e.to be about 12±1)
 Coolant flow rate: 80 – 100 LPM
 Lubricant oil:
 Lube oil: Way -68
 Check the MB diameter by dial snap gauge (refer it with std specimen).
 Check width of MB by width gauge.
 Check CP thrust by radius template.
 Check the finishing using the appropriate method.
 Maintenance:
 Note:
 To this machine a Marposs calliper is provided using which the diameter of the MB is
checked while machining.
 Before start of machining control, the radius at the corner of the grinder using diamond
dresser (radius at the corner should be as per std. provided). The machining operation is
shown in the fig.2.7
 The STD master used should kept in coolant to control its diamonds.

Fig. 2.7: MB Finish Grinding.

2.13 Operation No 13: CP Finish Grinding

 Operation name: CP finish grinding
 Machine name: LANDIS GRINDING MACHINE
Operation description:
 Speed of the grinder:550 rpm
 Speed of the work piece :25-30 rpm
 Feed: manually
 Indexing required in this operation which is done automatically by CNC system.
 Tool:
 Grinder diameter :1000mm
 Diamond dresser used to sharpen the grinder.
 Time:
 Job/shift:6
 Coolant oil:
 Coolant oil: WS600(soap oil)
 Temperature of coolant oil: 18-20°c
 Check the oil concentration for every shift (i.e. to be about 12±1).
 Coolant flow rate: 90-100lpm
 Lubricant oil:
 Lube oil: Way -68
 Check the CP diameter by dial snap gauge.
 Check width of CP by width gauge.
 Check CP thrust radius by radius template.
 Check the finishing of component using appropriate method.
 Maintenance:
 Note:
 As the feeding is manual check the diameter of CP at every time using dial snap gauge &
for clamping the work hydraulic system is used.
 Before start of machining control, the radius at the corner of the grinder & sharpen the
grinder using dresser (radius at corner should be as per the STD provided).

2.14 Operation 14: Pad Milling & Hole Drilling on Pad

 Operation name: Pad Milling & Hole Drilling on Pad
 Machine name: MILLING & DRILLING MACHINE
The operation of pad milling and hole drilling shown in table 2.3
Table 2.3: for both pad milling & hole drilling on pad.
Operation Speed Feed Time(min) Tool Material
(RPM) (automatic For of the
by CNC) (whole tool
job)
Pad milling 250 50mm/min 6:18 Milling cutter Carbide
alloy
Centering 250 50mm/min 4:8 Drill of diameter HSS
=12.5mm
Drilling (2 300 50mm/min 6:30 Drill(diameter=14.7mm) HSS
holes on
each pad)
Counter 300 50mm/min 7:49 Combination Carbide
boring tool(D1=16.67)
(D2=23mm)
Tapping 300 - 9:46 Tapping tool -
(rolled (M14.7*1.4)
type)
 Tool:
 Total milling time: 6:18 min
 Total drilling time: 26:36min
 Overall operation: 39:39min
 Coolant:
 Coolant oil: bio cool -100
 Check the coolant oil level for every shift & ensure its concentration is as per the std
provided.
 Lubrication system:
 Lube oil: Way68
 Check the lube level for every shift.
 Check the width of the pad.
 Check the holes drilled using plug gauges.
 Check the thread using thread plug gauge.
 Using receiving gauge check hole positions.
 Maintenance:
 Breakdown causes: coolant oil problem, electric problem, CNC problem, lubrication
system problems etc.
2.15 Operation No 15: End Drilling & Tapping

 Operation name: End drilling & Tapping
 Machine name: PRIDE DRILLING MACHINE
 Machine type: CNC Drilling Machine
 Flange end drilling: No. of holes =12 & one dowel hole.
The operation description of end drilling and tapping in flange end shown in the table2.4
Table 2.4: For end drilling and Tapping.
Operation Speed Feed Time Tool Material of

(RPM) (automatic (min)for (specification) the tool
by CNC) (whole job)
Drilling 1250 10mm/min 2.14 Drill (dia. Carbide
=19.18mm) alloy
Drilling 1250 10mm/min 1.96 Drill Carbide
(D=17.5mm) (dia.=17.5mm)
Tapping 250 10mm/min 5.32 Tapping Carbide
tool(M17.5*1.6)
Drilling 2000 10mm/min 0.4 Dowel Carbide
dowel hole tool(D=5.95mm)
Reaming 1250 10mm/min 0.7 Reaming tool HSS
(6.32mm)
Chamfering 1000 - 0.76 Chamfering tool Carbide
(7.10°*90°)
 Gear end drilling: No. Of holes =8 & one dowel hole.

The operational description of end drilling and tapping in gear end shown in table2.5
Table 2.5: For end drilling & tapping.
Operation Speed Feed Time (min Tool Material of
(RPM) (automatic for (whole (specification) the tool
by CNC ) job)
Drilling 1250 10mm/min 3.5 Drill (dia Carbide
=17.5mm) alloy
Drilling 1250 10mm/min 4.06 Drill (dia Carbide
(d=18.26mm) =18.26mm)
Tapping 250 10mm/min 5.32 Tapping tool Carbide
(M18.26*16)
Drilling 2000 10mm/min 0.26 Dowel tool Carbide
dowel hole (D=5.95mm)
Reaming 1250 10mm/min 1.12 Reaming tool HSS
(6.32mm)
Chamfering 1000 - 0.70 Chamfering Carbide
tool(7.10°*90°)

 Total time:
 For FLANGE end drilling: 26:11min
 For GEAR end drilling: 36:40min
 Overall operation time: 65:51min
 Coolant system:
 Coolant oil: bio cool – 100 oil
 Check the level of the coolant for every shift
 Lube oil: Way 68
 Check the level of lube oil for every day
 Check the hole positions using receiving gauge.
 Check the diameter of the drilled holes using the plug gauges.
 Check the thread using thread plug gauge.
 Check the depth of holes different diameters using Venire.
 Maintenance:
 Breakdown causes: coolant oil problem, electric problem, CNC problem, lubrication
system problem etc.
 Note:
 Drilling at both ends is done to do coupling (it joins the 2 rotating shafts).
 The tapping (internal threading) done is the rolled type tapping.
 Clamping of work piece is by manually.

2.16 Operation No 16: Keyway Milling

 Operation Name: Keyway Milling
 Machine name: JOYTI KEYWAY MILLING MACHINE
 Machine Type: Manual
 Machining description:
 Key way is done at both ends of crankshaft
 Key way type: WOODRUFF keyway
 Work piece is Stationary
 Speed of the Milling Cutter:180RPM
 Feed: Manual
 Tool:
 Milling cutter
 Material: HSS (High Speed Steel)
 Time:
 Time required at FE End:9.47min
 Time required at GE End:10.23min
 Overall operation time:20.10min
 Coolant System:
 Coolant oil: WS600
 Check the level of the coolant for every shift.
 Dimensional Inspection:
 Check the width of key slot using Width gauge.
 Check the depth of the slot.
 Maintenance:
 Preventive Maintenance is done as per plan set.
 Breakdown causes: Coolant oil problem, lubrication system problem clamping problems,
etc.
 Note:
 Key is used to connect two pieces in such a way that there is no relative motion between
them. The key way milling machine is shown in the fig.2.8
 Special milling cutter is used to produce woodruff keyway.
 Indexing done for proper positioning of the key, this is done manually.

Fig. 2.8: Key way milling.

2.17 Operation No 17: Belt Lapping

 Operation Name: Belt Lapping
 Machine Name: BOMBAY LATHE
 Machine type: Manual
 Purpose:
 Polishing of component
 Maintaining of diameter of MB, CP, FE, GE at all positions
 Operation Description:
 Speed of the work: 200rpm
 Using polish paper, the polishing is done manually.
 Using snap dial gauge diameter is checked every time.
 Time:
 Total polishing time: 3min
 Maintenance:
 Preventive maintenance is as per control plan.
 Breakdown causes: Lubrication system problems, Work clamping problems, etc.
 Note:
 Using polish paper polishes the surface of the component.
 Snap dial gauge is used to inspect the dia. of the component.
 No Cooling system is required.

2.18 Operation No 18: CNC Lapping

 Operation Name: CNC Lapping
 Machine name: CNC LAPPING MACHINE
 Purpose:
 For Super Finishing
 In this operation super finishing of all CP & MB, Big collar is done. The CNC lapping
machine is shown in fig.2.9
 Indexing required for CP finishing is done automatically by CNC system.
 For finishing thrust the reciprocating motion given to work using motor attached at head
end (reciprocating displacement should be limited up to 3.5-4mm only, which measured
by using Dial gauge).
 Initially work is clamped at correct position using stand provided at middle of machine
 It consists total 7 arms, in that 3 arms for rough & 3 arms for complete super finish &
remaining one arm is finishing the big collar.
 Then after finishing the operation measure Diameters of CP, MB, Collar using the
Micrometre& also checks finishing by appropriate method.
 Operation Time:
 Total time required to complete 1 job: 33.26min
 Jobs/shifts: 8-9
 Polish Paper:
 Norton Lapping film
 Coolant system:
 Coolant oil: ECOCUT HFN-5 oil
 Check the level of coolant for every day.
 Lube oil: Way 68
 Check the level of lube oil for every shift.
 Maintenance:
 Preventive maintenance is done as per the control plan (usually observation done for
every day & maintenance done for each month).
 Breakdown causes: Coolant, Lubrication system problems, electric problems, CNC
problems, etc.
 Note:
 Hydraulic system is used to clamp the work (Hydraulic oil used WAY46).
 In this machine the 40-micron Norton film is used for rough finish & 20-micron Norton
film used for full finish for CP & MB & for finishing the Collar 30-micron film is used.
 Check finishing after this.

Fig. 2.9: CNC lapping machine

2.19 Operation No 19: Loading & Balancing

 Operation Name: Loading and Balancing
 Machine Name: ABRO BALANCING MACHINE
 Purpose:
 Loading is done attaching counter weights to balance the crankshaft.
 Loading:
 In loading operation each 6kg counter weights are attached on pad by Nut & Bolt
arrangement.
 Separate machine is not required for loading.
 Balancing:
 Balancing is done on ABRO Balancing machine.
 In this operation work is made to rotate at speed of 300rpm & using probe sensor attached
to work the unbalancing observed on display in different planes (ABRO Software is used
to analysis the unbalancing in different planes).
 This soft's shows unbalancing plane & it is locating on in terms of angle.
 Then by manual indexing for required angle is done.
 If the extra material is present then it is removed by drilling the holes on counter weights
at indexed position. (for drilling feeding done manually).
 If the negative unbalance becomes then the counter weights are replaced by new one &
then again balance test is done.
 Note:
 In loading counter weights assembly dowel ring used to fit counter wt. in crankshaft pad
holes.
 In ABRO Balancing probe sensor is connected to work at head only.
 The ABRO software shows the positive unbalancing in terms of weight and in terms of
diameter, depth of hole to be drilled on pad at appropriate positions.

2.20 Operation No 20: Writing Job No. & Finish Cleaning

 Operation Name: Writing Job no & finish cleaning
 After balancing the crankshaft, the job number & counter weight No. are written on the
crankshaft is using MARKING MACHINE.
 Then verify the job number written at flange & no’s written on counter weights.
 Then check the oil holes using small steel balls passing through the holes.
 Then final inspection is done & check the dust level in oil holes using appropriate test.
 Clean work by plastic paper to remove oil content left on work after lapping operation.
 Then spray the VCR-412 oil on work with some high pressure.
 Then cover it with plastic paper & pack it to iron boxes.
 Then keep ready for EXPORT (Exported to TATA CUMMINS IND LTD).
TOTAL CYCLE TIME FOR THE MACHINING OF CRANKSHAFT (KV-12): 17

hours (approx.)

CHAPTER 3
QUALITY DEPARTMENT
Quality control, or QC for short, is a process by which entities review the quality of all
factors involved in production. This approach places on emphasis on three aspects.
1. Elements such as controls, job management, defined and well managed processes
performances & integrity criteria, & identification of records
2. Competence, such as knowledge, skills, experience, & qualifications
3. Soft elements, such as personnel, integrity, confidence, organizational, motivational, team
spirit & quality relationships.
Controls include product inspection where every product is examined visually, & often
using different instruments a fine detail before the product is sold into the external market.
Inspectors will be provided with lists & descriptions of unacceptable product inspection such
as cracks, surface or blemishes for example. The quality of outputs is at risk if any of these
three aspects is deficient in any way.
Quality control emphasizes testing of products to uncover defects & reporting to

management who make the decisions to allow or deny product release, whereas quality
assurance attempts to improve & stabilize production to avoid or at least minimize, issues
which led to the defect in first place. For contract work, particularly work awarded by
government agencies, quality control issues are among the top reasons for not renewing the
contract.
 Functions:
 Receiving inspection:
When the job imported from outside companies the receiving inspection should be done
to check dimensions & specification are as per the required & as per the imported
company
 In receiving inspection:
 All dimensions of the job should be inspected Ex. Length, diameters width
 Check material properties of the job Ex. Hardness
 Check for the cracks, defects in components
 In process inspection:
In process inspection of the job is done after different operations Ex. Linear check is done
after turning of GE & FE of crankshaft.
There are different inspections done for crankshaft while machining.

1. Linear check-01 after operation no.6:

This inspection is done after the induction hardening operation of the crankshaft. In this
inspection the linear dimensions are checked & bend occurred due to IH operation measured.
a) Check the linear dimensions of the job

b) Check the bend by using dial gauge
If any mismatching of dimensions work with std. control plan then report Will be sent
to upper level dept & corrective actions are taken.
2. Linear check-02 after operation no.8:

This inspection is done same as linear check. If any mismatching of dimensions work
with std. control plan then report will be sent to upper level dept & corrective actions are
taken.
3. Crack test after operation no.14:

Work piece is checked for cracks that occur during the machining process.
Machine name: MAGNIFIED CRACK TEST MACHINE.
 Procedure:
1. Clean the work piece completely & then wash it with mixture of kerosene oil & magnified
powder.
2. Work piece is subjected to shocks around 7-8 times & the work piece is electrically
magnetized.
3. UV rays are radiated on the work piece
4. Thus the cracks (FR or MR) are observed
5. If FR cracks are seen then it is concluded that the cracks have occurred during the forging
process, it is reported to the company from which the work piece is imported.
6. If MR cracks are observed then they are the ones that occurred during machining & the
corrective measures are taken.
4. Inspection after operation no.17:

All linear dimensions are checked & compared with standards & the finishing of the
work piece is checked.

 Final inspection:
1. Work piece is taken to the standard room & is cleaned neatly
2. Diameters of all CP, MB, GF, FE, COLLAR, GROOVES electric gauges & compared with
standards.
3. Position of all holes are checked using receiving gauges.
4. Check the width, oil hole diameters, GE &FE end hole diameters & it is also checked for
Threading using respective gauges.
5. Check the hardness of jobs.
6. Check the dust present in the oil holes using the appropriate methods.
7. If the dimensions of the work piece don’t match with the standards then corrective
measures are taken.
 Ferro test:
In this test all dimensions of the work piece including the dimensions that cannot be
checked manually; hence they are checked using CMM (coordinate measuring machine).
 Process audit:
The inspectional results of a work piece are cross checked with the results of the
standard work piece. It is done during the in-process inspection.
 Dock audit:
The inspectional results of a work piece are cross checks with the results of the
standard work piece. It is done during final inspection.
 Calibration:
In calibration the measurements used for the dimensional analysis are calibrated every
time to reduce the errors that can occur during the measuring. If an instrument giving the high
error then it is replaced by another with low error instrument. Some standards are followed
while calibration that depends on the companies.
 Corrective action:
When the dimensions of the work piece are not matched with the std work sheet some
corrective actions are taken.

 Inspection Parameters:
The inspection parameters of the crankshaft is shown in the Table 3.1
Table 3.1: Inspection Parameters.
Sl. No. Diameter Lower Master Higher Master

Value in Inches Value in Inches
1 Damper Diameter 4.3599 4.3611
2 GE Oil Seal Diameter 4.3740 4.3751
3 GE Gear Mounting Diameter 4.3800 4.3810
4 Main Journal Diameter 6.4984 6.5002
5 Pin Diameter 4.2484 4.2500
6 FE Gear Mounting Diameter 7.2580 7.2601
7 FE Oil Seal Diameter 7.2479 7.2502
 Gauges used for Inspection:

 Micrometre:
Using the Micrometre check the width of the various parts like Main Bearing, Crank pin,
Key slots the micrometre is shown in the Fig.3.1
Fig.3.1: Micrometre

 Plug Gauge:
The plug is used to checking the drilled oil holes in the crankshaft shown in the fig.3.2
Fig.3.2: Plug gauge
 Throw gauge:
Check the throw using the throw gauge shown in the fig.3.3 this gauge is used in checking
the throw of the main bearing and connecting pin.
Fig.3.3: Throw gauge

Chapter 4
ROLE OF STUDENT DURING INTERNSHIP
During the internship period in Ashok Iron Works ltd, The Machining and Assembly
division, I undergone many operations (Milling, Drilling, Roughing, Grinding, furnacing,
Hole drilling etc.) on the crankshafts. I Observed different types of crankshafts (KV12,
KV16, V28) machined in respective machines. Got to know different types of tools
specification in different operations, finally final inspection is done and product has been
dispatched.

CHAPTER 5
CONCLUSION
In review this internship has been an excellent and rewarding experience. I have been
able to meet and network with so many people that I am sure will be able to help me with
opportunities in the future.
As an engineering student it is important to know the industrial ( machining operations)

working environment. These types of visit help us to know about industry work ethics,
problems faced, dedication required. I learnt how the management works, workers skills,
knowledge required for testing processes carried out in the Maching and Assembly
Division.Beacause of this exposure, further we will concentrate on studies by industrial
perspectice; so that I can be ready to face the challenges and solve the problems in any area
after completing engineering.


ASHOKA

Cargado por

Información del documento

Título original

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

ASHOKA

Cargado por

Copyright:

Formatos disponibles

ASHOK IRON WORKS PVT LTD.

1.1 Company profile

Chairman: Mr. Ashok S. Humbarnadi

Joint Managing Director: Mr. Jayant Humbarnadi

Director: Mr. V. S. Katkar

Address - Mazagaon Road, Udyambag,

1.2 Main Features of Company-

DEPARTMENT OF MECHANICAL ENGINEERING

Plant: Ashok Iron Works Unit-III

 MAHINDRA & MAHINDRA

DEPARTMENT OF MECHANICAL ENGINEERING

1.4 Process Flow Diagram

DEPARTMENT OF MECHANICAL ENGINEERING

2.1 Operation No1: Connecting Pin Milling

DEPARTMENT OF MECHANICAL ENGINEERING

2.2 Operation No 2: Main Bearing Turning

DEPARTMENT OF MECHANICAL ENGINEERING

Fig. 2.1: Main Bearing Turning.

DEPARTMENT OF MECHANICAL ENGINEERING

2.3 Operation No 3: Oil Hole Drilling

Operation description of oil hole drilling is shown in the table 2.1

Operation Speed(rpm) Feed Time (Min) Material Tool change

DEPARTMENT OF MECHANICAL ENGINEERING

Fig 2.2: Oil hole drilling.

DEPARTMENT OF MECHANICAL ENGINEERING

2.4 Operation No 4: Counter Boring

DEPARTMENT OF MECHANICAL ENGINEERING

2.5 Operation No 5: Buffing of Oil Holes

DEPARTMENT OF MECHANICAL ENGINEERING

2.6 Operation No 6: Induction Hardening

DEPARTMENT OF MECHANICAL ENGINEERING

Fig.2.3: Induction Hardening.

DEPARTMENT OF MECHANICAL ENGINEERING

2.7 Operation No 7: Furnacing

DEPARTMENT OF MECHANICAL ENGINEERING

Fig. 2.4: Furnacing.

DEPARTMENT OF MECHANICAL ENGINEERING

2.8 Operation No 8: Shot Blasting

DEPARTMENT OF MECHANICAL ENGINEERING

Fig.2.5: Shot blasting.

DEPARTMENT OF MECHANICAL ENGINEERING

2.9 Operation No 9: MB Rough Grinding

DEPARTMENT OF MECHANICAL ENGINEERING

2.10 Operation No 10: CP Rough Grinding

DEPARTMENT OF MECHANICAL ENGINEERING

Fig. 2.6: CP Rough Grinding.

DEPARTMENT OF MECHANICAL ENGINEERING

2.11 Operation No 11: FE & GE Turning & Groove Cutting

DEPARTMENT OF MECHANICAL ENGINEERING

2.12 Operation No 12: MB Finish Grinding

DEPARTMENT OF MECHANICAL ENGINEERING

Fig. 2.7: MB Finish Grinding.

DEPARTMENT OF MECHANICAL ENGINEERING

2.13 Operation No 13: CP Finish Grinding

DEPARTMENT OF MECHANICAL ENGINEERING

2.14 Operation 14: Pad Milling & Hole Drilling on Pad

2.15 Operation No 15: End Drilling & Tapping

Operation Speed Feed Time Tool Material of

 Gear end drilling: No. Of holes =8 & one dowel hole.

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

2.16 Operation No 16: Keyway Milling

DEPARTMENT OF MECHANICAL ENGINEERING