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A Project on manufacturing of Rear Wheel Drum
- 1. A Project on manufacturing of Rear Wheel Drum By HEMAPRASATH MECHANICAL ENGG. (B.TECH) SRM UNIVERSITY CHENNAI To Mr.ISHWAR PRASAD MANAGER OF LINE-2 MACHINE SHOP SCOOTERS INDIA LIMITED LUCKNOW SCOOTERS INDIA LIMITED
- 2. CERTIFICATE This is to certify that this summer training report has been prepared by HEMAPRASATH (B.TECH-MECH) from SRM UNIV ERSITY , CHENNAI in the partial fulfilment of the requirement of vocational training at SCOOTERS INDIA LIMITED, LUCKNOW. The matter was analysed by candidate under my guidance and this report embodies the work done by him We wish him a bright future Guide Ishwar Prasad Manager Machine shop line-2
- 3. Scooters India LTD Lucknow ACKNOWLEDGEMENT At this very outset I sincerely acknowledge with gratitude the guidance and support rendered to me by Training Centre and Machine Shop Department of Scooters India LTD without which this training would not have materialized I would like to thank Mr S.B.SINGH (H.R. SCOOTERS INDIA LIMITED) for providing me an opportunity to interact and take guidance from engineers of Machine shop department. During my summer training at Machine Shop I felt like a family member and learn a lot about how a team works to achieve the target, how industry works towards continuous improvement in the direction of the cost efficient, quality, customer satisfaction and society at large.
- 4. I would like to thank Mr.IswarPrasad (Dy.Manager,Machine Shop), and all engineers, staff and workers of machine shop department, for providing me proper guidance , site visiting , help and other facilities makes my summer training very interesting and easier. Preface Summer Training plays an important role in engineering course as it give practical knowledge of the things that we study theoretically in our course. It is my great pleasure in presenting the report on manufacturing of Rear Wheel Drum and suggests improvements based on observational made at various stages of manufacturing, by the learned fellow and faculty members of Scooters India LTD, Lucknow
- 5. It also gives knowledge about total production process and quality management and how engineers work to utilize the resources properly and efficiently PRODUCT PROFILE
- 11. ASSEMBLY: Thecomponents manufacturedintheplant as well as thoseboughthavetobefinallyassembledtomakethe product three wheelers. In the process many sub- assemblies too are involved. However, two main assemblies worth mentioning are engine
- 12. assembly and vehicle assembly. Both are conveyorised. Every 5 mins a three wheelers rolls down the conveyor. The vehicle conveyor has 23 stations. Speed can be adjusted to meet increasing demand. DICASTING: Thebiggestdiecastingshopinthispartofthecountry handles bothAluminiumandZinc alloys. Equippedwith pressure die casting machines of 160,250,400 and 1000 tons locking pressure, the metal is fed to machinesfromindividualholdingfurnaceof75/150kg,
- 13. Aluminiumcapacity. The shop based on projected area, is capable of producing aluminiumdiecasting upto5 kg inweight. Theshopisbackedbychemicalsandmetallurgicallabs as also with a die maintenance section. The well- equipped machineries are used in two shifts that produce all the accessories required by this organization. The die casting of various types of components like Gear box housing, Crankcase, Front wheel drum, rear wheel drum, Bell housing, Magneto flange,Cylinderhead,LowerandUpperhandlebar, Levers, Differential housing cover, Brake shoe are undertaken. Die casting components for fulfilling customers requirementarealsotakenup.Someofourcustomers are BHEL, Bhopal, Greaves India Limited, Aurangabad to whom supplying the Gear boxes and 422 cc
- 14. aluminiumEnginesaresupplied. MACHINE SHOP: Machine shop has a wide variety of machines like General purposemachine, Special purposemachines, Multi-purpose machines, Multi-spindle automatic
- 15. machines, Single spindle automatic machines etc., whichis mainly working onsingle shift thougheight different lines. Line no. 2 is basically machining the Aluminium components. Crankshaft and Cylinder machining is usually doneonLineno. 3, Lineno. 4is thegrinding linewherethegrinding process is done. Heat treatment is performed in Line no. 5, while different turning of shafts and gear shaping and shaving arecarriedonLineno. 6 and7includes the functioning of gear manufacturing process mainly broaching,hobbing,finishing,turning,gearshavingetc. Machining of different levers, centre less grinding of tubes&shafts,threadrollingoperationsisachievedin Lineno.9.Blankturningofgear&machiningofparts Is done on multi- spindle & single spindle automatic machine. Engine
- 16. components &some vehicle components are prime productions. FABRICATION: The fabrication operations are carried out in two department wise. Press shop & welding shop. The press shopis equippedwith20presses rangingfrom
- 17. 10tonnesto550tones.Pressesarefedbysheetscut tosizeonshearingmachinesof30006&25003mm size.Componentsrangingfromwasher tocabinroof& door (10001200mm) are being processed in this shop. The welding shop is equipped with battery of spot welding, MIG welding, Sam welding & arc welding machines. CO2weldingis extensivelyusedfor getting closetoleranceonweldedstructure. Thedepartment has its ownauxiliaryshopfor maintenancefor tool & die. SURFACE TREATEMENT & PAINTING: Paintshopincludesthreesectionnamelypaintsection, spray phosphate section, pickling. Paints section
- 18. includes two conventions painting &spray booths & one electrostatic painting plant. The 1st one is called conventional primepaintingareBulow230 spraygun &pressurefit tanks. Thevarious types of frames like diesel 750, mini petrol, mini diesel, diesel floor mounting, diesel Nepal, diesel scrubber, electric vehicle are painted here. The conventional booth is known as conventional finish booth. Here the frame accessorieslikecabinfront, rooftop, frontfrock, axle housing is painted. In electrostatic plant the accessories of the frame, the component of lighter weight andminimumsizelikesilencer, pillar &various bracketsarepaintedhere. In spray phosphating the main is to clean the component before painting or to make surface accordingtopaint requirement. After phosphatingthe
- 19. productsgoestopassivationforconvertingferrousto ferric for painting needed. The products come from welding shop, press shop & machine shop to phosphating&after theprocess is beinggonetothe vehicleassembly.
- 20. FOUNDRY: Thefoundry, most moderninthis part of thecountry, canproduceallgradesofgreycastironaswellasSG iron.Infact,ithadbeeninnovativetofindnewprocess of modulation, for whichit was grantedtwopatterns. Equipped with an induction melting furnace, shell moulding machine & core scooter, green sand facilities,isothermalheattreatmentfurnace,onesand Muller machine, two shat blasting equipment, its normal rangeof productionweight is upto8 kgona patternplateof450600mm. The foundry is not fully loaded with its captive requirements.Sparecapacityis utilisedfor producing sophisticated casting of prestigious customer like BHEL, Indianrailways, aerospace, brakes Indialimited, Cromptongreaveslimited.
- 21. Thetwotypeofmouldingisdonehere.Sandmoulding &GreenMoulding.Thefoundrycanmanufactureawide rangeof products namely Crankcaseflange, Magneto motor, Engine output flange, adapted plate for electricalvehicle.
- 22. TOOL ROOM: The tool roomis a cell where brain combines with versatility to evoke the new era of invention. The designs of tool coming from main tool planning department are implementedhere. The tool roomis furnishedwithwell-equippedmachineriesnamely- CNC machine (Taiwan), Jig Boring machine (Czech republic), Jig grinding machine (Switzerland), Profile Grinding machine (Germany), Die sliding machine (Czechrepublic),EDM(USA). Toolroomevokeahighperformanceoutputconsisting almost 99.9% of companys requirement : One die casting dieper year, 1-10 press tool per month, 8-10 jigs per month, 10-12 gauges per month &400 C.T. toolspermonths.
- 23. These machines are efficiently used to manufacturing different tools & dies like jigs & fixtures, Gauges, Cutting tools, Forging dies, Die casting dies, Developments Items etc. The different activities like Turning, Milling different shapes, Grinding, Heat treatment, Jig boring, Jig Grinding, checking in the standard room, heat treatment accordingtothejobrequirement, final inspectionare undertakenintheinthetoolroom.
- 28. COMPONENTS: Back Plate: The Back Plate serves as the base onwhichall the componentsareassembled.Itattachestotheaxleand forms a solid surface for the wheel cylinder, brake shoes and assorted hardware. Since all the braking REAR WHEEL DRUM
- 29. operationexerts pressureonthebackplate, it needs tobeverystrongandwearresistant. Leavers for Emergency or parking brakes and automatic brake shoe adjuster were also added in recentyears. Brake Drum: TheBrakeDrumisgenerallymadeofaspecial typeof cast iron which is heat conductive and wears resistance. It is positioned very close to the brake shoewithout actuallytouchingit, androtates withthe wheelandaxle. Wheel Cylinder: Onewheelcylinderisusedforeachwheel.Twopistons operate the shoes, one at each end of the wheel
- 30. cylinder.Whenhydraulicpressurefro mthe master cylinder acts uponthe pistoncup, the pistonsare Pushedtowards the shoes, forcing themagainst the drum. Brake Shoe: Brakeshoesaretypicallymadeoftwopiecesofsheet steel weldedtogether. The frictionmaterial is either rivetedtotheliningtableorattachedwithadhesive. Automatic Self Adjuster: The self-adjuster is used to adjust the distance
- 31. betweenthebrakeshoeandthedrumautomaticallyas brakeshoeswear. PHOTOS OF REAR WHEEL DRUM WHILE MANUFACTURING AND ITS MACHINE:
- 33. STEPS INVOLVED IN MANUFACTURING OF R.W.DRUM 1. IN DIE CASTING SHOP: Machinethat isusedindiecasting shopisHMT BULLET 250Ton adnois10041. 250Tonisthelockingpressureappliedduringthe manufacturingofR.W.Drum. Cast ironandsteel hubis usedfor manufacturing of outer circular ring and inner circular ring respectively. DICOAT WATERWASTE AND DICOAT
- 34. 40(unchidova) is used to prevent sticking the material tothedie. Molten Aluminum alloy is used for its manufacturingwhosemeltingpointisnearly 600属c, but in die casting shop it is heated up to 642属c. Design provided in this structure so that it can absorbtheexcessloadanddoesntgetaffected. Pressure die casting is used for the whole manufacturing, twotypesofdieisusedoneisfixed andoneismoving. Timelimits: Timeformovingofpiston: 14sec
- 35. Lockopentime: 12sec Standardtime: 15sec Total standardtime takeninmanufacturing of an R.W.Drumindiecastingshopis21sec.