SUMMER TRAINING PROJECTREPORT

INDIA YAMAHA MOTOR PVT. LTD.

SUBMITTED BY:-PRABHAT TIWARI

B.TECHMECHANICAL DEPARTMENT

SESSION: 2012-2016

DIT, AMITY GROUP OF INSTITUTIONGREATER NOIDA, U.P

(AFFILIATED TO UTTAR PRADESH TECHNICAL UNIVERSITY)

PREFACE

As a part of course curriculum of Bachelor of Technology we were asked to undergo 4 to 6 weeks summer training in any organization so as to give us exposure to practical skill and competence to get us familiar with various activities taking place in the organization.

Our institute also believe in close and continuous Industrial Academy interaction in order to enhance the capability of student to imbibe rich and practical exposure useful for the corporate world.

I have put my sincere efforts to accomplish my objectives within the stipulated time. I have worked to my optimum potential to achieve desired goals. I came across some difficulties to make my objective a reality. With the kind help and genuine interest and the guidance of my supervisor, I tried my level best to conduct a research to gain a thorough knowledge about the project. I put the best of my efforts to bring out this piece of work; if anywhere, something is found unacceptable or unnecessary to the theme valuable suggestions are thankfully acknowledged

Thanks and Regards

Yours sincerelyPrabhat Tiwari

ACKOWLEDGEMENT

I would like to express my gratitude to all the people who provided me with support and guidance throughout the course of my summer internship program

Firstly I would like to thank Mr. Bhavesh Kumar (HR department), Vijay Khanna (HR department) and Shaima Tayyab (HR department) for giving me an opportunity to undergo summer training at INDIA YAMAHA MOTORS PVT LTD, Mathura road, Faridabad. I am deeply indebted to Mr. S.K Gulati and Mr. Rajendra Kumar (Crankshaft department) without the supervision and continued guidance of whom it wouldn’t have been possible to complete this project.

I would also like to thank Mr. A.K Sharma for providing me this wonderful opportunity to work with the YAMAHA family.

Thank you

Prabhat Tiwari

CONTENTS

1. Preface

2. Acknowledgement

3. Content

4. Overview

5. About Yamaha Motors

5.1. History

5.2. About India Yamaha Motors Pvt. Ltd

6. Manufacturing

6.1. Raw Material

6.2. The manufacturing process

6.3. Quality Control

7. Faridabad Plant

7.1. Gear

7.2. Camshaft

7.3. Body Cylinder

7.4. Head Cylinder

7.5. Axle

7.6. Connecting Rod

7.7. Crank

7.8. Crankcase Cover

8. Heat Treatment

OVERVIEWINDIAN AUTOMOBILE INDUSTRYOver a period of more than two decades the Indian Automobile industry has been driving its own growth through phases. The entry of Suzuki Corporation in Indian passenger car manufacturing is often pointed as the first sign of India turning to a market economy. Since then the automobile sector witnessed rapid growth year after year. By late 90’s the industry reached self-reliance in engine and component manufacturing from the status of large scale importer.

With comparatively higher rate of economic growth rate index against that of great global powers. India has become a hub of domestic and export business. The automobile sector has been contributing its share has been contributing its share to the shining economic performance of India in recent years.

With the Indian middle class earning higher per capita income, morepeople are ready to own private vehicles including cars and two-wheelers. Product movements and manned services have boosted inthe sales of medium and sized commercial vehicles for passenger andgoods transport. Side by side with fresh vehicle sales growth, theautomotive components sector has witnessed big growth. The domesticauto components consumption has crossed rupees 9000 crores and anexport of one half size of this figure

As per Society of Indian Automobile Manufacturers (SIAM) the market share of each segment of the industry is as follows:

ABOUT YAMAHA MOTORS

HISTORY

Yamaha's history goes back over a hundred years to 1887 whenTorakusu Yamaha founded the company, which began producingreed organs. The Yamaha Corporation in Japan (then Nippon GakkiCo., Ltd.) has grown to become the world's largest manufacturer ofa full line of musical instruments, and a leading producer ofaudio/visual products, semiconductors and other computer relatedproducts, sporting goods, home appliances and furniture, specialtymetals, machine tools, and industrial robots.The Yamaha Motor Corporation, Ltd., begun on July 1, 1955, is amajor part of the entire Yamaha group, but is a separatelymanaged business entity from the Yamaha Corporation. TheYamaha Motor Corporation is the second largest manufacturer ofmotorcycles in the world. Yamaha Motor Corporation owns itswholly-owned subsidiary in the U.S. called Yamaha MotorCorporation, USA, that is handling not only motorcycles, but alsosnow mobiles, golf carts, outboard engines, and water vehicles,under the brand name of Yamaha as well.In 1954 production of the first motorcycles began, a simple 125ccsingle-cylinder two-stroke. It was a copy of the German DKWdesign, which the British BSA Company had also copied in thepost-war era and manufactured as the Bantam.

About India Yamaha Motor Pvt. Ltd.

Yamaha made its initial foray into India in 1985. Subsequently, it entered into a 50:50 joint-venture with the Escorts Group in1996. However, in August 2001, Yamaha acquired its remainingstake becoming a 100% subsidiary of Yamaha Motor Co., Ltd, Japan (YMC). In 2008, Mitsui & Co., Ltd. entered into anagreement with YMC to become a joint investor in themotorcycle manufacturing company "India Yamaha MotorPrivate Limited (IYM)".IYM operates from its state-of-the-art-manufacturing units atSurajpur in Uttar Pradesh and Faridabad in Haryana and

produces motorcycles both for domestic and export markets.With a strong workforce of more than 2,000 employees, IYM ishighly customer-driven and has a countrywide network of over400 dealers.

MANUFACTURINGIndia Yamaha Motor’s manufacturing facilities comprises of 2 state-of-the-art Plants at Faridabad (Haryana) and Surajpur (Uttar Pradesh). The infrastructure at both the plants support of motorcycles and its parts for the domestic as well as overseas market. It has In-house facility for Machining, Casting, Welding process as well as finishing processes of Electroplating and Painting till the assembly line.

The stringent Quality Assurance norms ensure that its motorcycles meet the reputed International standard of excellence in every sphere.

RAW MATERIAL:-

The primary raw materials used in the manufacture of the body of motorcycle are metal, plastic and rubber. The motorcycle frame is composed almost completely of metal. The frame may be overlaid with plastic. The tires are composed of rubber. The seat is made from a synthetic substance, such as polyurethane.

The cylinder piston, made of aluminium alloy is an essential component of engine. It is fitted with piston rings made of cast iron. The crankshaft and crankcase are made of aluminium. The engine also contains a cylinder barrel, typically made of cast iron or light alloy.

THE MANUFACTURING PROCESS:-

1. Raw materials as well as parts and components arrive at the manufacturing plant by truck. As part of just-in-time delivery system on which many plants are scheduled, the materials and parts are delivered at the place where they are used or installed.

2. Manufacturing begins in the weld department with computer-controlled fabrication of the frame from high strength frame materials. Components

are formed out of tubular metal and/or hollow metal shells fashioned from sheet metal shells fashioned from sheet metal. The various sections are welded together. This process involves manual, automatic and robotic equipment.

3. In the plastic department, small plastic resin pellets are melted and injected into molds under high pressure to form various plastic body trim parts. This process is known as injection molding.

4. Plastic and metal parts and components are painted in booths in the paint department using a process known as powder-coating. A powder coating apparatus works like a large spray-painter, dispersing paint through a pressurized system evenly across the metal frame.

5. Painted parts are sent via overhead conveyors or tow motor to assemble department where they are installed on the frame of the motorcycle.

6. The engine is mounted in the painted frame, and various other components are fitted as the motorcycle is sent down the assembly line.

7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags, light, radios and hundreds of other parts are installed on the motorcycle frame.

QUALITY CONTROL:-

At the end of the manufacturing line and assembly line, quality control inspectors undertake a visual inspection of the motorcycle and its part’s finishing, painted finish and fit of parts. The quality control inspectors also feel the motorcycles with gloved hands to detect any bumps or defects in the finish. Each motorcycle is tested on a dynamometer.

Inspectors accelerate the motorcycle from 0-60mph. During the acceleration, the “dyno” tests for acceleration and braking, shifting, wheel alignment, headlight and taillight alignment and function, horn function and exhaust emissions. The finished product must meet international standards for performance and safety. After the dyno test, a final inspection is made of the completed motorcycle.

FARIDABAD PLANT

The manufacturing unit of Faridabad plant constitutes Casting, Machining, Welding, Heat treatment and Painting of parts of two wheelers of IYM. Following are the parts of two wheelers manufactures in Faridabad Plant of IYM:-

1. Gear2. Axle Main3. Cylinder Head4. Cylinder body5. Crank6. Crankcase7. Cover crankcase8. Cam and Cam shaft9. Connecting rod

GEAR

GEAR BLANK from the vendor is brought to the Faridabad plant for manufacturing of gears. Then it is passed through the following processes:-

Turning, facing, boring and chamferingHobbingBroachingMarkingWashingShavingHeat treatment

Hobbing

Hobbing is a machining process for making gears, splines, and spockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the gear blank by a series of cuts made by a cutting tool called hob. Compared to other gear forming processes it is

relatively inexpensive but still quite accurate, thus it is used for broad range of parts and quantities.

It is most widely used gear cutting process for creating spur and helical gear and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

USES

Hobbing is used to make following types of finished goods:

Cycloid gear Helical gears Involute gear Ratchets Splines Sprockets Spur gears Worm gears

Hobbing is used to produce most throated worm wheels but certain tooth profiles cannot be hobbed. If any portion of hob profile is perpendicular to axis then it will have no cutting clearance generated by usual backing off process and it will not cut well.

BROACHING

For very large gears or splines a vertical broach is used. It consists of a vertical rail that carries a single tooth cutter formed to create the tooth shape. A rotary table and a Y axis are the customary axes available. Some machines will cut to a depth on the Y axis and index the rotary table automatically. The largest gear are produced on these machines.

Other operation such as broaching work particularly well for cutting teeth on the inside. The downside to this is that it is expensive and different broaches are required to make different sized gears. Therefore it is mostly used in very high production runs.

MARKING

Marking is done on the Primary Gear and Gear Balance Weight. In this process in mark is made on a certain distance from the centre of the gear on both types of gear so that at time of assembly all the gear should be properly mounted such as no misalignment is present in gear assembly, otherwise the transmission system of vehicle fails during the operation.

CAMSHAFT

Camshafts can be made out of several different types of material. These include Chilled iron casting and Billet steel.

Chilled Iron Casting: this is a good choice for volume production. A chilled iron camshaft has a resistance against wear because the camshaft lobes have been chilled, generally making them harder.

Billet Steel: when a high quality camshaft is required, engine builder and camshaft manufacturers choose to make the camshaft from steel billet. One example being EN40b. When manufacturing a camshaft from EN40b, the camshaft will also be heat treated via gas nitriding, which changes the micro-structure of the material. It gives a surface hardness of 55-60 HRC. These types of camshafts can be used in high-performance engines.

Processes

Various process involve in the manufacturing of cam shaft according to operating machines are:-

FacingTurning operationKeyway drilling and tapping operationOil hole drilling operationCam grinding operationGrinding operationLapping operationWashing operation

BODY CYLINDER

Body of cylinder of engine in made of aluminium in Casting shop of Faridabad plant. In casting liquid aluminium is poured into the mold, which contains the hollow cavity of desired shape, and then allowed to solidify. The solidify part is known as casting which is ejected or broken out of the mold to complete the process.

Initially it has poor surface finish and defects, so it is brought to the Machining shop for giving desired accurate dimension and surface finish. Machine/Operator-wise operation done on the Body cylinder are:-

Camera Vision testingFace milling, drilling and boring A faceMilling, dowell and drilling B faceMilling, drilling and tapping C faceDowell and rough boring B faceFine boring Internal diameter honing Internal diameter testing Air plug gauge settingOil extracting machiningDate code markingWashing and air cleaningLeak testing

HEAD CYLINDER

Like Body cylinder it is also made up of Aluminium in casting shop and according to its desired shape then it is also brought to the Machine shop for removal of defects, giving more accurate dimension and surface finish.

Machine-wise process involve in the manufacturing of Head cylinder are:-

Spot facing and drillingMilling and drillingRight fixture Exhaust facing, rough guide hole drilling & Left side inlet

facing/guide hole drilling

Right side exhaust, left side inlet facing and threadingRight side exhaust, left side exhaust boring and threadingRight side facing, left side inlet facing, drilling and tappingRight side exhaust, left side inlet rocker millingRight side exhaust, left side inlet parent boringParent bore inspectionRight side spark hole facing, threading, left side hole drilling and reamingRough cambore, face milling, drilling and threadingMid-washingAir blow procedureAir plug gauge inspectionSeat and guide pressExhaust valve seat machining Inlet valve seat machiningCambore fine boring, drilling and reamingDeburringFinal washingAir blow procedureLeak inspection

AXLE MAIN

The method includes heating a billet at a heating station to a predetermined temperature, forging the heated billet at a forging station to form a machined axle. This axle is brought to the Faridabad plant from vendor and processed in machining shop for desired accurate shape, dimension and surface finish.

The process involves are:-

TurningDeburringDrillingOil hole drilling

WashingHobbingThreading

CONNECTING ROD

A standard shape of connecting rod with poor surface finish is brought from vendor to the Faridabad plant where whereas operation is done on it in Machining and heat treatment shop to give it proper accurate dimension, good surface finish and hardness.

Operation carried out in Machining shop are:-Small end drillingSmall end internal diameter drillingSmall end champeringBig end boring and champeringSmall end oil hole drilling

Heat treatment: In heat treatment shop for carburizing it is kept for 9 hours at 930 degree celsius and then for diffusion it is kept for 4 hours

Then again it is brought to the machine shop for:

Both end face grindingHoningWashing

CRANK

Like some other parts forged crank is also bought from vendor of standard shape and poor surface finish. In machining shop it various operations are done on it to give it a defect less and accurate dimension and also good surface finish. The machine-wise operations done over it are:-

Centering and facingPin turningPin hole boringThread rollingKeyway milling Induction hardeningOuter diameter grindingThrust facing Internal diameter grinding

COVER CRANKCASE

Like engine cylinder it is also manufactured in casting shop of Faridabad plant by melting the metal and poring it into the mold and then extracting the solidify casting from the the mold. From casting shop this cover crankcase is brought to the machine shop for the following process to give it a good surface finish and preparing its desired dimensions:-

Milling, dowell and boringDrilling, tapping, boring of screw holeDrilling and chamferingWashingAir-blowVisual inspection

HEAT TREATMENTHeat treating is a group of industrial and metal working processes used to alter the physical and sometimes chemical properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials such as glass, Heat treatment involves the use of heating or chilling normally to extreme temperatures to achieve a desired result such as hardening or softening of material. Heat treatment techniques include annealing, case hardening, precipitation strengthening, tempering and quenching. It is noteworthy that while the term heat treatment applies only to processes where heating and cooling are done for specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding.

TECHNIQUES:The heat treatment techniques used for manufacturing of parts of two wheeler in Faridabad plant are:-

Annealing

It consists of heating a metal to a specific temperature and then cooling at a rate that will produce a refined microstructure. It is often used to soften a metal for cold working to improve machinability or to enhance properties like electrical conductivity

Normalizing

Normalizing is a technique used to provide uniformity in grain size and composition throughout an alloy. The term is often used for ferrous alloys that have been heated above the upper critical temperature and then cooled in open air.

Stress relieving

Stress relieving is a technique to remove or reduce the internal stresses created in a metal. These stresses may be caused in a number of mays, ranging from cold working to non-uniform cooling. Stress relieving is usually accomplished by heating a metal below the lower critical temperature and then cooling uniformly.

Aging

Some metal are classified as precipitation hardening metals. When a precipitation hardening alloy is quenched, its alloying elements will be trapped in solution, resulting in a soft metal. A “solutionized” metal will allow the alloying element to diffuse through the microstructure and form intermetallic particles. These intermetallic particles will nucleate and fall out solution and act as a reinforcing phase, thereby increasing the strength of the alloy. Alloys may age “naturally” meaning that the precipitates form at room temperature, or they may age “artificially” when precipitates only form at elevated temperatures. In some applications, naturally aging alloy may be stored in a freezer to prevent hardening until after further operation-assembly of rivets, for example, may be easier with a softer part.

Quenching

Quenching is a process of cooling a metal very quickly. This is most often done to produce a martensite transformation. In ferrous alloys, this will often produce a harder metal, while non-ferrous alloys will usually become softer than normal.