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ITS ALL ABOUT SWARAJ
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SIX MONTHS INDUSTRIAL TRAINING
AtPUNJAB TRACTORS LIMITED,
MOHALIPHASE-IV
SUBMITTED BY:-AJIT SINGH
R NO. 41711004SEVENTH SEMESTER
MECHANICAL ENGINEERING
INSTITUTE OF ENGG & TECHNOLOGY BHADDAL ( ROPAR )
PREFACE
“Training is an investment and hence should be able to get due returns in
terms of better quality of workmen and Engineering for future.”
As a part of Punjab Technical University’s academic calendar Industrial
training provides Engineering students practical exposure to the ways in
which work is carried out in industries. The various problems faced and how
to tackle these problems in an industry.
P.T.L. today is one of the major and largest Tractor Producing Industry in
our country. It is competing at global level by providing their best
performing machines to their customers.
As concerned with my Industrial training it is of my best opportunity
during my Engineering to learn many things about Automobile Industry
through this Industry.
During my training I learn many things that would pay to me in my near
future. I pay thanks to the training faculty of our college and to staff and
operators of P.T.L. Swaraj Tractor division for their co-operation during my
Industrial Training.
ACKNOWLEDGEMENT
Before we get into the thick of fog, I would like to say that it was a
great pleasure & privilege for me to have the opportunity of undertaking the
training at PUNJAB TRACTOR LIMITED, MOHALI, for a period of 6
months as my 7th semester project work for the Bachelor of Tech. Education
at DEPARTMENT OF MECHANICAL ENGINEERING, S.U.S.C.E.T.
TANGORI. I would like to thank the PTL for providing me such an
opportunity.
Firstly I would like to express my deep gratitude to the Head of the
training department Mr. J SINGH for his continuous help & guidance during
the training tenure.
I am extremely grateful to Mr. M.C Gupta (Sr. manager vdc dept)
who helped me at every stage by providing mean opportunity to visit various
vendors.
My heartily thank to Mr. Purshotam k Sharma and Mr. S.K Saini who
were my project coordinator & my guide throughout the project works. They
always went out of their way to help me at all times. Their experience &
knowledge motivated me to bring out the best in times.
I am sure that the knowledge & information that I have gained during
this period would be of immense value for my growth in the field of
industrial engineering.
Finally I thank all those to many to single out by name, who helped
me no small measure, by sharing their immense knowledge gained over
years of experiences.
(AJIT Singh)
TRACTOR INDUSTRY IN INDIA
A LOOK AT THE INDUSTRY
India being a predominantly agricultural country, where
agriculture is the life and blood of the economy, it has been a traditional
manufacturer of different types of farm machinery. However the use of
advanced agricultural techniques in India started only in earl sixties.
Modernization in Indian industry is only post independence
phenomenon. One of the achievements of green revolution has been that
the farmers realized the advantage of using tractors in agricultural
industry.
It has been established that there is a close relationship between
the growth rate in the food grain production & intensity of
tractorisation. Increasing benefits of the mechanization have resulted in
an increase in the tractor demand & thereby tractor production over
the years. The density of tractor varies from state to state with Punjab
taking the lead at 65 tractors per 1000 hectares of irrigated land. With
the total land currently under irrigation being a small fraction of the
total irrigation potential of 1134 lakh hectares, a steady demand for
tractors in the near future can be anticipated.
“ORIGIN OF THE WORD “SWARAJ” In Hindi, the word “SWARAJ” means “Freedom from Bondage”. Since
P.T.L. was the only first largest tractor project in India, moreover fully based
upon Indian technology. So “SWARAJ” was appropriately chosen as its
brand name. SWARAJ GROUP sells its product under this brand name.
POSITION OF SWARAJ PRODUCTS IN MARKET With more than 2 lacs of tractors & harvester combines operating in Indian
farms, SWARAJ are now a well-established brand name in country.
SWARAJ is now an internationally recognized name in the developing
world.
The products of SWARAJ are not only restricted to Indian market but
they had entered in international market. SWARAJ tractors find an
important place in developing countries like Ghana, Tanzania, Zambia,
Kenya, Sudan, Uganda, Indonesia & Malaysia, etc. they are also sending
their combines to South Korea having first A.C. cabin combine in India.
Long way back, they had also transported the machined rims to Japan, a
project millions of dollars.
MERGER WITH MAHINDRA&MAHINDRA IN
YEAR 2007
M&M’s president (farm equipment sector) Anjani kumar Choudhari,
who took charge as PTL’s chairman and said: “Swaraj has tremendous
brand value in many northern markets and we are going to exploit it
fully.
M&M bagged the bid at about Rest 360 per share, and is acquiring about 43
per cent stake in the Chandigarh -based tractor firm for close to RUPEES
1,000 core in an all-cash deal.
The 43 per cent stake includes 29 per cent owned by private equity firm and
14.2 per cent by the Delhi-based Burman family.
It was the second largest tractor company a few years ago and we would be
promoting Swaraj aggressively to regain its lost market share. Some price
improvements in the product are also being planned, which would be
followed by a publicity campaign.”
While both the tractor brands would exist independently, a synergy in
production and other back-end operations has been planned. M&M would
utilize the low-cost vendors of PTL for its own tractors and eventually have
a common vendor base for both the products.
“We are planning major capital investment for modernization and expansion
of foundry operations. There is a huge shortage of casting capacity in the
market, so a major integration of the PTL’s foundry business with M&M
operations is being planned.
The company is also planning an expansion of PTL’s combined harvester
(mechanized harvesting vehicle) manufacturing facility.
HISTORY
The Indian Tractor Industries, as it is now, is a major segment of its
engineering industry. However till 1974, Indian firms assembling semi
knocked down (SKD) kits in collaboration with foreign manufactures met
the tractor requirements of the country largely through imports & partly.
Though the first Tractor Company was set up in India in 1960, but the
growth in real terms started from 1974, when the government banned the
import of tractors. Today India is the largest tractor producing and
consuming country. In an effort to reduce imports & develop indigenous
technology, the government, permitted setting up of the major
manufacturing companies.
1. Eicher Good Earth 1960
2. TAFE 1964
3. International Tractors 1965
4. Escorts Tractors 1966
5. Ford Tractors 1971
6. HMT 1973
7. Punjab Tractors 1974
8. Kirloskar 1974
9. Harsha 1975
10 Auto Tractors 1981
.11. Universal Tractors 1982
INDIAN TRACTOR INDUSTRY MARKET DIMENSION
GEOGRAPHICALLY
TERRITORY %age of Domestic Sales
North (Punjab, Haryana & Uttar Pradesh) 32%Central (Madhya Pradesh & Rajasthan) 26%East (Bihar, West Bengal, Orissa & Assam) 10%
West (Gujarat & Maharashtra) 12%South (Andhra Pradesh, Tamil Nadu, Karnataka & Kerala) 20%
SEGMENTWISE
HP Range %age of Total Sale
Up to 30 HP
31-40 HP
Above 40 HP
19%
51%
30%
PTL’S BIRTH
Keeping in mind Punjab agrarian economy it was decided by Punjab Govt.
to encourage the growth of industries which complements Punjab’s
agricultural growth. This task was entrusted to P.S.I.D.C. that was played a
major role in bringing Punjab to threshold of industrial revolution. With the
dual objective of industrial & agricultural growth, P.T.L. was established on
27th June 1974.
LOCATION
The factory is located at S.A.S. Nagar, the important industrial town of
Punjab, 5 kms. from Chandigarh. This factory was among the first to be set
up in this industrial town. The company is managed by board of Directors,
while the day to day operations are managed by Vice chairman & M.D. of
the company.
GROWTH OF PTL
PUNJAB TRACTOR LIMITED started with an annual capacity of
five thousand tractors & with a capital of Rs. 3.7 crores. It went into
commercial production in the year 1974; its first production was 26.6
BHP tractors given the name SWARAJ-720. Ever since then P.T.L. has
not looked back. In the first twenty years of existence its capacity has
been increased to 24,000 per annum, which is a considerable
achievement by any standards. Besides tractors, it has added a host of
other products to its range, which includes:
Harvesting Combine.
Fork Lifters.
Agriculture implements.
Automotive casting.
Punjab Tractors Ltd (PTL) is one of the leading manufacturers of
tractors in India. PTL has been known as the industry out performer since
inception. Even when the industry grew at a CAGR of 6.1% during 1991-
2000, PTL grew at the CAGR of 11.9%. In terms of market share, PTL is the
second largest player after M & M in FY2001 with a market share of 18.1%.
PTL tractors are sold under the ‘Swaraj’ brand name. PTL has strong market
share of around 20% in the northern region with the highest share in Punjab
and Haryana and 16% in the western regions and southern regions of India.
In the east the company accounts for 11% market share. The tractor sales
accounted for 83.3% of PTL's turnover in FY2001 whereas the harvester-
combines, forklifts and spare parts accounted for the balance. Industry
basics The Indian tractor market is dominated by low price, rugged,
versatile and low to medium powered tractors; the main reason being the
inability of farmers to invest in farm mechanization. Tractors are categorized
on the basis of horse power (HP) of the engine. In India, the popular range of
tractors is 20-40 HP compared to 60 HP in Europe and 90 HP in the USA.
Though large tractors were economically unviable in India, there has been
an increasing demand for high-powered tractors due to soil conditions,
particularly in states of MP, Gujarat and Maharashtra. But more recently,
higher-powered tractors are also being sold in states like Punjab where it is
considered as a status symbol. Tractors available in India are 1/4th of the
prices of similar powered tractors internationally or in developed countries.
Availability of credit is the most crucial factor impacting tractor demand, as
in India 90% of the tractors are financed by bank credit at concessional rates.
Increased use of irrigation facilities, shift towards multi-cropping,
consolidation of lands holdings, promotion of co-operatives and higher
investment in agriculture also contributes to higher tractor demand. The
tractor segment comprises players like Eicher, Escorts, HMT, Punjab
Tractors, M&M, TAFE, Sonalika, which control about 98% market
share. India is the world’s largest market in tractors since 1996. A few
international players like Case New Holland, John Deere and Steyr have also
set up facilities in India. But these players have entered the higher-powered
category and, thus, pose little threat to the existing players who enjoy
advantages of established distribution/service network and strong brand
equity. Punjab Tractors is promoted mainly by Punjab State Industrial
Development Corporation Limited and has acquired the second highest
market share in the tractor segment from 9.1% in 1975. In 1970, PTL had
major competition from other companies like Eicher, Tractors and Farm
Equipment (TAFE), Mahindra & Mahindra (M&M), Escorts and HMT. PTL
is one of the leaders in its business and has put up a heady performance in
contrast to other private sector players. As against other players, which
report a ROCE of 15% on an average, PTL has consistently remained at
about 50% in the last few years though the industry is capital-intensive.
Punjab Tractor is the only major tractor company, which entered this
business without any foreign collaboration. The company has beefed up its
R&D capabilities in the last two to three years. PTL’s Swaraj-735 is in a
class of its own and has been benchmarked by its competitors to which 16
new features have been added. PTL has single – mindedly focused on
increasing its market share in tractors. Current Scenario During the first
half of 2001-02 PTL increased its market share from 18.5% to 21.4%. With
the total industry volumes plummeting by 16.6% the sales of PTL fell only a
trifle 3.1%. Under these circumstances, though the revenue has fallen by a
0.38% the operating profitability has risen by 1.03%. PTL garnered the
operating margins of 19.4% in the first half of FY2001-02, while the lead
players like M&M Escorts and Eicher have reported operating margins of
4.4%, 0.7% and 2.9% respectively. The Net Profit has increased by 1.4% to
Rs.564 million and the contribution of 40-50HP tractors has increased by
30%, which indicates higher margins from bigger tractors due to a strong
foothold in Punjab and Haryana markets.
SWARAJ’S YEARLY PROGRESS
1965: Govt. of India's research institute (CMERI) at Durgapur initiates
design and development of SWARAJ tractor based on indigenous know-
how.
1970: Punjab Govt. through PSIDC acquires SWARAJ tractor's design from
CMERI and establishes Punjab Tractors Ltd. (PTL) for its
commercialization.
1971-73: PTL sets up SWARAJ Project for 5,000 tractors per annum at a
capital outlay of Rs. 37.0 million with an equity base of Rs 11.0 million.
1974: Swaraj 724 (26.5 HP) tractor commercially introduced.
1975: 2nd tractor model SWARAJ 735(39 HP) developed by own R&D,
commercially introduced.
1978: 3rd Tractor model SWARAJ 720 (19.5 HP) developed by own R&D,
commercially introduced. Maiden equity divided declared.
1980: Guided by social concerns and responsibility, PTL takes over PSIDC's
sick scooters unit - Punjab Scooters Ltd. (subsequently renamed as
SWARAJ Automotives Ltd.) India's first Self propelled Harvester
Combine - SWARAJ 8100 developed by own R&D, commercially
introduced. SWARAJ Foundry Division set up in backward area.
1983: 4th Tractor Model - SWARAJ 855 (55 HP) developed by own R&D,
commercially introduced. Expansion of annual capacity to 12,000 tractors
per annum at Plant 1.
1984: SWARAJ MAZDA Ltd. promoted in technical and financial
collaboration with Mazda Motor Corps. & Sumitomo Corpn. Japan for
manufacture of Light Commercial Vehicles. PTL's equity participation is Rs.
30.4 million (29%) and that of Mazda and Sumitomo's Rs. 27.0 million
(26%).
1985: SWARAJ Industrial Forklift Trucks developed by own R&D,
commercially introduced.
1986: SWARAJ ENGINES Ltd. promoted in technical and financial
collaboration with Kirloskar Oil Engines Ltd.(KOEL) for manufacture of
diesel engines. PTL's equity participation is Rs. 6.9 million (33%) and that
of KOEL's Rs 3.6 million (17%).
1995: Setup of tractor Plant II at Village Chappercheri with annual capacity
of 12,000 per annum.
1998: Commencement of expansion to 60,000 tractors (30,000 at each
plant). Capital outlay of Rs 1000 million, funded mainly through internal
accruals.
1999: 5th and 6th tractor models - SWARAJ 733 (34 HP) & SWARAJ 744
(48 HP) developed by own R&D, commercially introduced.
2000: Expansion of annual tractor capacity to 60,000 completed.
2006: merger with M&M at management level
INTERNATIONAL AND NATIONAL
COLLABORATION OF SWARAJ GROUP
Swaraj group has entered into technical and financial collaborations with
various national and international companies.
1 Swaraj Mazda Limited was set with technical and financial
collaborations with Mazda Motors Corporation of Japan.
2 Swaraj Combine Division was entered into with Komatsu Forklift
Company of Japan for manufacturing fork lifters.
3 Swaraj Engines Limited was set up in technical and financial
collaboration with Kirloskar Oil Engines Limited, Pune for
manufacturing diesel engines.
EXPORT PERFORMANCE OF SWARAJ GROUP
Having established Swaraj in the national market, the group made a
determined start in the 1980’s it to get a foothold in the international market.
Over the years a large number of Swaraj Tractors and other implements have
been exported to many African countries such as Zambia, Kenya, Tanzania
and Nigeria and also in the Middle East and south East Asia. Recently it has
exported some engines to U.S.A. Nepal and Sri-Lanka.
RESEARCH AND DEVELOPMENT IN
SWARAJ GROUPResearch and development is an integral and sustaining department of any
organization, which want to sustain its place in the ever-developing
industrial environment. The emphasis on research and development in the
Swaraj Group is proved by a long list of new products that have been
introduced and established in the years ever since the establishment of
Swaraj Group. There is a separate research and development unit of the
group located at phase 7 of S.A.S. Nagar (MOHALI). Research work is
carried out in this unit and design work is accomplished presently, the
research and development is going on with various new products.
VARIOUS DIVISIONS OF SWARAJ GROUP:- Swaraj consists of SIX divisions:
1. Swaraj Tractors Division.
2. Swaraj Mazda Ltd.
3. Swaraj combine Ltd.
4. Swaraj automotive Ltd.
5. Swaraj foundry division
6. Swaraj Engines Ltd.
SWARAJ TRACTORS DIVISION:-
It is located in Phase-IV, SAS Nagar. The construction work of PTL was
started in March 1972 and the first batch rolled out on 14 th November 1973.
It started with an annual capacity of 5000 tractors with a capital of Rs. 37
million. In 1974 it went into commercial production with Swaraj 724 26.5
BHP tractors as its first model. During its 22 year of production, it has not
only expanded its manufacturing capacity to more than 24000 tractors per
annum but adds more products into its manufacturing range. Its product
range includes the following.
TRACTORS SPECIFICATION MFG BY SWARAJ:-
Swaraj 724 26.5 BHP 1974
Swaraj 735 39.0 BHP 1975
Swaraj 720 19.5 BHP 1985
Swaraj 855 55.0 BHP 1987
Swaraj 744 44.0 BHP 1995
Swaraj 733 33.0 BHP 2000
Swaraj 939 35.0 BHP 2004
Swaraj 834 34.0 BHP 2005
Swaraj 978 78.0 BHP 2005
1. SWARAJ 724 24.0 BHP
2. SWARAJ 733 33.0 BHP
3. SWARAJ 744 44.0 BHP
4. SWARAJ 722 22.0 BHP
5. SWARAJ 735 35.0 BHP
6. SWARAJ 855 55.0 BHP
7. SWARAJ 939 39.0 BHP
8. SWARAJ 978 78.0 BHP
9. SWARAJ 834 34.0 BHP
10.SWARAJ 957 57.0 BHP
SWARAJ ENGINES LIMITED
Swaraj engines limited are a part of Swaraj enterprise. Swaraj Engines
Ltd., situated at phase 9, Industrial Area Mohali. This plant was
established in technical and financial collaboration with Kirloskar oil
engines Ltd. For manufacturing diesel engines for Swaraj Tractor Division.
The Governor of Punjab S.S. Ray paid the foundation stone of the factory on
29th Dec. 1987. It started production from 28th Dec. 1988.
This plant produces engines in the range of 20hp to 50hp. This plant had
produced 18000 engines in the first year of his production. But now it is
producing 50 engines averagely every day. There are 300,000 tractors
working successfully in the fields which are having engines of Swaraj
engines limited .This plant is a boon for agricultural automotive industry.
The various engine models being produced at SEL are:-
1. RV2 ----------- two cylinders ; 24 B.H.P.
2. RV3 ----------- three cylinders ; 39.5 B.H.P.
3. S15 ----------- Single cylinder ; 25 B.H.P.
4. RB33 ----------- three cylinders ; 55 B.H.P.
5. RB30 ----------- three cylinders ; 44 B.H.P.
These engines are sent to the Swaraj tractor division where these are fitted
on various model tractors. The S-15 engines are manufactured in the Swaraj
combine division and are fitted on Swaraj 722 model tractors.
INTRODUCTION The manufacturing of Tractor is performed in various steps. It is
manufactured after passing through various processes in various shops.
Firstly, various operations on various parts are performed in the L.M.S.
(Light Machine Section) and H.M.S. (Heavy Machine Section). In H.M.S.
generally there are four major heavy parts that are given proper machining
operations. These include Gear Box Casing, Differential Housing, Trumpet
Housing and Rear Cover. Similarly, in L.M.S. the light parts are given
proper machining. These include various parts such as Gears, Shafts, Cage
Assembly casing etc.
In Heat Treatment Shop, the light parts such gears, shafts etc are
given the heat treatment to ensure their strength. Firstly the part after passing
through various operations in L.M.S. is taken to the Heat Treatment Shop.
Here the part is kept in the furnace for suitable time period up to certain high
temperature. Then it is taken to the Quenching tank where it is dipped in the
oil tank. After that it is taken to washing tank for washing of dirt and oil etc.
Then it is taken to the Assembly line.
In Assembly line various parts are being assembled into a single unit
termed “Tractor”. During assembling the various parts are being fitted
according to the stage. This would includes the assembly of important parts
such as Rear Cover, Gear Box, Differential Housing and trumpet Housing.
Firstly the Various sub-parts of the Rear Cover are being fitted. Then the
various parts such as gears, shafts, bearing, oil rings, clutch actuator and
circlip etc are fitted into the Gear Box. After that both the Rear Cover and
the Gear Box are taken to the line where Gear Box if fitted ahead of the
Differential Housing whereas the Rear Cover on the Top. Then various
things such as Brakes, P.T.O. Shaft, Cage Assembly, Trumpet Housing etc
are fitted to the Differential Housing. Then this whole assembly is fitted
with the engine against the Gear Box.
After whole assembly is fitted with the Engine, this assembly is taken
to the Chassis Paint Area where it is washed and dry followed by Paint on
the chassis.
Then the tractor reaches to the Final stage where certain electrical and
other accessories such as Battery with Battery cover, Steering Wheel,
radiator etc are fitted. Proper level of Engine oil is also filled into the
Differential and Gear Box. Greasing of various parts is also performed with
Grease Gun. After that the Tractor is taken out of the line after taken it out
from the hooks. This stage is termed as “Dismounting Stage”.
Then the Testing of the Tractor is performed which include the
checking for vibrations, noise, brakes, oil level and other factors that effects
the performance of tractor.
At last there is pre-dispatch inspection done by quality department.
Touching of paint removal of bubbles from stickers etc is done here.
LIGHT MACHINE SHOP
Introduction:
L M S is the largest section of the factory. All transmission
components like shafts and gears used in tractors are manufactured here.
L.M.S comprises of 117 machines. Except the bevel gear generator & gear
shaver, which have been imported from W M W & Churchill of Germany
respectively, all other machines are from HMT Ltd. 160 highly experienced
operators and inspectors manned this shop.
Types of machines:
S.No. M/C Description Job Operations
Bull Gear Line
1. ECO-5 CNC Bull Gear Turning 2. Broaching machine Bull Gear Cutting Internal Spline 3. Gear hobbing
machineBull Gear Cutting Outer Spline
4. Deburring machine Bull gear For removing rough edges
5. Shaving Bull Gear Shaving or
machine finishing
Bull Pinion Shaft Line
6. Center Facing machine
BP shaft Facing, Centering
7. Femco Turning machine
BP shaft Rough, Finish turning (first 4 steps)
8. Femco WNCL-30 BP shaft Rough, Finish turning (next 6 steps)
9. COOPER BP shaft Spline cutting
10. HMT H400 BP shaft Gear cutting 11. Shaving machine BP shaft Shaving
Cage Assembly
12. VMC-40Right cage Drilling, Chamfering,
Grooving, Tapping, Facing
13. Boring machineCage assembly Boring (both sides)
14. Cylindrical Grinding machine
Cage assembly Grinding
15. HMT HMC-320 Cage assembly Cross drilling
Other Machines
16. Lichberr (HMT) Hobbing Gear cutting
17. Cooper Gear idle cluster Cutting18. Parisuda AHG 80
CNCIntermediate shaft Grinding
19. HMT Radial drill drilling20. GCI 300 CNC Bevel Gear Grinding21. VMC-500 vertical
milling machineMilling, Drilling
22. WIDMA drilling Drilling
machine23. SPILOTE Copy turning Lathe24. PS-180 Gear shaper(not
bevel)Spline cutting
25. Spectra grind 600 Grinding
DIFFERENT MANUFACTURING OPERATIONS IN L
M S:
Facing: It is the operation of finishing the ends of the work to
make the ends flat and smooth and to make the piece of required
length.
Under cutting: It is similar to grooving operation but is performed
inside a hole.
Chamfering: It is operation of beveling the extreme end of the
work pieces, chamfer is provided for better look.
Rough turning: In this operation max Metal is removed and very
little over size dimensions are left for further machining.
Finish turning: Here minimum metal is removed and very fine
finish is obtained on the work surface.
Grooving: It is operation of turning the groove or neck in order to
terminate a thread or to provide adequate clearance enable nut to
pass freely on threaded work piece to remove burs and to protect
the work piece from being damaged.
Knurling: It is the process of embossing a diamond shaped regular
pattern on the surface of the work piece using a special knurling
tool.
Broaching: It is the method of metal removal by a tool that has
successively higher cutting edges in a fixed path. Each tooth
removes a fixed amount of material.
Drilling: It is the process of making hole in an object by forcing a
grind means to abrade to wear away by abrasion or to sharpen. In
grinding the metal is removed by the means of rotating abrasive
wheel it is rotating a rotating tool called drill.
Boring: It is the process of enlarging a hole that has already been
drilled.
Grinding: It is generally used for sharpening the cutting tool,
grinding threads and better surface finish etc.
Shaping: The process of cutting gears on the shaper is known as
Shaping. The tool used in shaping for teeth’s cutting is a multi-
point cutting tool.
Hobbing:
Hob: - Hob is a cutting tool used for cutting gears or similar form
gears by the generating principle.
A Hob resembles a worm in appearance its cutting teeth on
the outside of a cylindrical body following a helical path
corresponding to the thread of a worm. It is useful to think of a hob
as a cylinder with a series of racks being parallel to the hob axis or
nearly so and each one slightly displaced axially with respect to the
preceding racks. As the hob rotates in fixed rotation with the blank
each row of teeth successively cuts the next portion of the gear
tooth spaces.
Hob material: -
1. High speed steel (HSS) - M2
2. HSS with 8% cobalt (M35)
3. Power metallurgy (ASP 30)
4. Carbide.
5. Tool steel.
HEAVY MACHINE SHOP (H. M. S.)
All heavy casting of tractors is machined in this shop with the help of
variety of special machine (SPM). These machines are tailors made by IIMT
to suit component requirements. In addition, facilities of this shop include
general-purpose turning, drilling and milling machines. About 20 SPM and
30 GPM are installed in a covered area of 47,000 sq. Ft. At a cost of 20
million, 2600 tones of castings are machined every year on a two-shift basis.
In addition to the machining of casting for the tractor, some jobs are also
performed for SWARAJ MAZDA LIMITED.
COMPONENTS MACHINED IN THE SHOP:
Gearbox housing (Material R-33, Casting, 180-230 BHN, 76-Kg wt.).
Differential housing.
Rear cover.
Trumpet housing
CONCEPT OF DOWELLING
The main aim or purpose of doweling is to act as a guide to the work
piece setting proposes prior to machining. Use of this process helps in
reducing the setting time considerably during machining of heavy
components. It is very difficult to set the work piece in required position
prior to machining, this process is very time consuming, hence when
initially the cast piece is brought dowel holes are drilled which act as the
pivot around which the whole machining takes place. Dowel hole act as the
reference point for machining of all the other holes on the work piece all the
operation to be performed on the work piece are taken in reference to the
dowel holes thus the hole act as the reference to all the operations.
PROCESS OF SETTING PRIOR TO DOWELING: Before the dowelling the cast piece is clamped manually, there are
three points to be touched. It follows the phenomena of 3-2-1, which means
that we have to restrict the motion in three directions i.e. x, y, z direction,
two to restrict horizontal and vertical motion and one act as reference point,
this process is known as “butt and clamp”. By dowelling it is all about
locate and clamp hence there is lot of saving of time.
REFERENCING:
Dowel act as reference, all the dimension of the work piece i.e. all
the machining operations are from the reference of Dowel hole.
Types of machines:
Sr.No. M/C Description Operations
1.HMC (multipurpose machine), HDC
Milling, Drilling, Dowel holes
2.Duplex milling machine (cutter 500 mm, total length made –490 mm, 26 inserts 1 viper (inserts for rough cut, viper for finish)
Milling
3.HMC 500 Internal milling,
drilling CD hole (39 mm for outer, 24.2 for inner),
4.Boring machine Rough Boring
5.Boring machine Finish Boring
6.Turning Lathe Turning
7.Cross hole Drilling
8.HMT HDC-S Drilling (4 holes for
connecting rod 2 inner 2 outside)
9.HMT HMC 500 S Drilling, Spot facing
10.Turning Finish turning
11.Radial drilling machine Drilling, Reaming,
Tapping, Chamfering
Trumpet Assembly12.
Two way boring machine Rough Boring13.
RAYAUTO (7 tools work at a time)
Rough turning, Facing
14.Boring machine Finish Boring
15.HMT SBCNC 35 Finishing (outer face)
16.SPM Drilling, Tapping
17.TICO multipurpose machine Milling, Drilling,
TappingRear
Cover Assembly
18.Free Spindle SPM Milling(1 Vertical,2
horizontal)19.
CNC milling machine Milling20
Horizontal HC 630 CNC Drilling, Boring, Milling
21.VA 50 Drilling, Milling,
Tapping22.
XLO Boring (one way)
HEAT TREATMENT SHOP
Heat treatment shop plays a very important role in every industry. In
automobile industry all the gear and shafts need to be heat treated to impart
desired strength and increase life of the component. The H.T. shop at PTL is
equipped with several gas carbonizing furnaces, quenching tanks, induction
hardening machines and shot blasting furnaces.
Heat Treatment is an operation or combination of operations involving
heating and cooling of metals and alloys in the solid state to produce certain
desired properties. All the heat treatment processes may be considered to
consist of three main parts:
1. The heating of the metal to pre-determined temperature.
2. The soaking of the metal at that temperature until the structure
becomes uniform throughout the mass.
3. The cooling of the metal at some pre-determined rate to cause the
formation of desirable structures within the metal/alloy for the
desired purposes.
PURPOSES OF THE HEAT TREATMENT
Changes in properties result from the micro-structural changes in the
material produced by heat treatment operation. However, these serve one or
more of the following purposes:
1. Improve machinability.
2. Relieve internal stresses.
3. Improve mechanical properties such as ductility, strength,
hardness, toughness etc.
4. Change in grain size.
5. Increase resistance to heat and corrosion.
METHODS OF HEAT TREATMENT
Various methods depending upon the nature of job .i.e. it material, use etc
are employed for giving then Heat Treatment. These methods used are:
1 Annealing
2 Normalizing
3 Hardening
4 Quenching
5 Tempering
6 Case Hardening
a) carburizing
b) Cyaniding
7 Induction Heating.
ANNEALING:-
Annealing means softening of the material by heating and cooling process.
The cooling stage may be performed by regulating the fall of the
temperature in the furnace or by buried the article in sand or lime, and
quenching in oil or water, according to the material being treated.
NORMALISING :-
In this process the material is heated steadily through out its mass to just
beyond the critical temperature, and then withdrawn from the furnace and
allowed to cool in still air. With the normalizing process there is not soaking
period, for the work is held at the desired temperature for a period only
sufficient to give uniformity through out the mass.
Main purposes of the normalizing are:
1 To remove the effects of previous over heating and thus place the
material in good mechanical condition.
2 To remove the internal stresses caused by cooling from the molten state,
by cold working or by rough machining.
3 To soften the work prior to further hardening or tempering.
HARDENING:-
The operation of hardening is applied to all the tools and some important
machine parts intended for especially heavy duty service, as well as to all
machine parts made of alloy steel. Hardening of steels is done to increase
the strength and wear properties.
The process consists of:
1. Heating the steel to temperature above critical point,
2. Holding at this temperature for a considerable period,
3. Quenching (rapid cooling) in water, oil or molten sand bath.
Alloy steel and high speed steel are heated for hardening to about 1,100oC to
1300oC and cooled in the current of air.
QUENCHING:-
Quenching is the act of rapidly cooling the hot steel to harden the steel. Oil
is used when a slower cooling rate is desired. Oil quenching results in
fumes, spills, and sometimes a fire hazard.
TEMPERING:-
It is an operation to reduce the internal stress and brittleness. With plain
carbon steel, tempering operation consist in slowly heating the hardened
material from room temperature up to maximum of about 600oC and then
quenching in water or oil, the temperature and length of soaking period
being dependent in service requirement. Thus if plain carbon steel is to be
hard without any appreciable ductility, a temperature of about 150oC will be
required.
CASE HARDENING (CARBURISING):-
It is method of producing hard surface on steel. The steel used for this
purpose is usually a low carbon steel of about 0.15% carbon, which does not
respond appreciable to heat treatment. In course of the process, the outer
layer is converted into high carbon steel with a carbon content ranging from
0.9% to 1.2% carbon.
INDUCTION HEATING:-
It means the heating of ferrous metal by induced electrical current prior to
the hardening quench. In this process, analysis of the surface steel is not
changed, the hardening being accomplished by an extremely rapid heating
and quenching of the wearing surface which has no effect on the interior
core. The hardness obtained is the same as obtained in conventional
treatment and depends upon carbon content.
The heating effect is due to the induced eddy current in water or oil,
the temperature and length of soaking period being dependent on service
requirement. Thus, if plain carbon steel is to be hard without any appreciable
ductility, a temperature of about 150oC will be required.
SHOT BLASTING:-
Bombarding the component with lead filings does shot blasting. The reason
for shot blasting is to clean the surface i.e. removes scales and unwanted
material from the component.
This process of case hardening is use to harden the gears & shafts of the
tractor. But we know that as the hardness of any substance increases, the
brittleness of the material is also increases.
PAINT SHOP Paint Shop is the place where the different sheet metal components
are painted. They are made to pass through various chemicals before they
are actually painted. The painting method opted is that of Spray Painting.
NEED FOR PAINTING:-
Long life
Rust resistance
Better look (more appealing)
The various operations performed in paint shop are:
Surface Preparation (Pre Treatment Cell) - carried out for sheets and
rims.
Painting – JOST 1(dash board, rear frame, front shield, top bonnet),
JOST 2(fenders, side panel), CHASIS BOOTH (washing, primer,
washing zones), FINAL TOUCH UP.
Inspection
Rejection (Reprocessing)-for sheets and rims.
NEED FOR SURFACE PREPERATION:-
1. for removing
Organic compounds (oil, grease)
Inorganic compounds (oxides, peroxides)
2. Better paint adhesion
3. Eliminate chances of reoccurring of dust
METHODS OF SURFACE PREPERATION:-
Rubbing surface with sand paper
By shot blasting
By buffing
By chemical process
Here in PTL we make use of chemical process
CHEMICAL PROCESS:-
This process includes:
Degreasing
Rinsing (avoid transfer of caustic contents into next acidic process
otherwise next acidic process will get disturbed)
Derusting
Rinsing
Surface activation
PROCESS CHEMICAL CONC DIP TIME
Degreasing H.D.S-5 65-70 5-7minutes
Derusting Rusto-225 12-17 5-7minutes
Phosphating+Tunn
er (KNO3)
Phos-509 30(+-2) 7-8minutes
Surface activation S.C.C PH 8-9 1 Dip
Passivation SEALANT-27 1-2 1 Dip
Dryer 3-4 minutes
Phosphating (done so as to form a thin layer of coating on part so
that no surface remains unpainted)
Rinsing
Passivation (done so as to avoid paint penetrating through certain
section of part body’s surface)
Drying
PAINTING:-
The process (sheet and rim painting) includes
Full Primer + one coat of paint (30-40 microns)
Flash off (This is the distance given so as to allow paint to dry)
Baking (120-130 degree centigrade)
Rubbing
Cleaning with tag rag
Final painting
Flash off
Baking
CHASIS PAINTING:-
Washing
Drying
Primer painting
Flash off
Final painting
Flash off
Baking
After painting inspection is carried out inspection is carried out and the
product is passed or rejected
Various parameters checked are:
Depth of penetration of paint
Thickness of paint coating
Smoothness
Uniformity
REASONS FOR REJECTION OF PAINTED
COMPONENTS:-
Flow
Less paint
Pin hole
Crow footing
Shade Variation
Dust
Vender fault
ASSEMBLY SHOP
The Assembly at SWARAJ TRACTOR DIVISION deals with the
assembly of tractor models 722, 724, 733, 735, 744, and 834. Assembly is
the joining of various constituents to form a final product. The assembly
process is carried out on the main line, which has various sub assemblies
along its length. Assembly shop can be divided in two main areas: -
1) Before paint area
2) After paint area.
CLASSIFICATION OF ASSEMBLY AREA: -
The area before painting can further be divided into sub assemblies/ loops
namely
Differential loop.
Gearbox loop.
Rear cover loop.
Engine assembly loop.
DIFFERENTIAL LOOP:-
Differential casting mounted on trolley after washing.
Bull pinion Shaft left and right fitted.
Cage assembly fitted. It consists of:
1. Crown wheel.
2. Tail pinion assembly.
3. Roller bearing.
4. Bevel wheels.
5. PTO shaft fitted.
6. Rear axle/trumpet is fitted.
7. PTO shifter assembly fitted.
8. Gearbox assembly is lifted.
9. Rear cover assembly fitted.
10. Brakes are fitted.
11.Parking brake.
12.Suction pipe
13.PTO cover
14. Trailer hook is fitted.
15. Angle bracket is fitted.
16. Rocket link is fitted.
17. Footboard is fitted.
18. Clutch pedal is fitted.
GEAR BOX LOOP:-
Gearbox housing mounted on trolley.
Drive shaft & input shaft assembly.
Output shaft assembly.
Lay shaft and connecting shaft assembly.
Shifter rod assembly.
Steering assembly.
GEAR BOX:-
The gearbox used in the tractors being manufactured by the P.T.L. is
of the “SLIDING MESH TYPE”. This is the simplest type of gearbox. The
power comes from the 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 fixed to it and as such they are all the time rotating when the engine
is running. The clutch is engaged three direct and one reverse speed are
attained on suitably moving the gear on the main shaft by means of selector
mechanism.
