24-09-2014, 03:07 PM
ABSTRACT OF PROJECT DONE Industrial exposure is the most crucial part of the technical studies in which astudent is able to synchronize his technical knowledge with practicalknowledge gained in any of the organization in which he gets his trainingfrom. I was allotted a project titled, �Methods involved in the process of Production of REAR AXLE, in ESCORTS INDIA PVT LTD, FARMTRAC DIVISION�. I hope that the word of my project communicates the actual experiencegained with subtlety and precision, which is unapproachable, by any othermeans. From the medium of this project report, I would like to thank each andevery honorable employee of ESCORTS INDIA PVT LTD FARMTRAC DIVISION,who has helped me to gain all the knowledge in the respective productionshop, where production process was involved.
PROJECT REPORT 8.1 PROJECT NAME: TO PRODUCT THE REAR AXLE OF TRACTOR 8.2 INTRODUCTION
Industrial exposure is the most crucial part of the technical studies in which astudent is able to synchronize his technical knowledge with practicalknowledge gained in any of the organization in which he gets his trainingfrom. I was allotted a project titled, “Methods involved in the process ofProduction of REAR AXLE, in ESCORTS INDIA PVT LTD, FARMTRAC DIVISION”.
I hope that the word of my project communicates the actual experiencegained with subtlety and precision, which is unapproachable, by any othermeans. From the medium of this project report, I would like to thank each andevery honorable employee of ESCORTS INDIA PVT LTD FARMTRAC DIVISION,who has helped me to gain all the knowledge in the respective productionshop, where production process was involved.
8.3 METHODS INVOLVED INTHE PROCESS OF PRODUCTION OF REARAXLE.
DESIGN OF THE REAR AXLE SHAFT
Figure 21: DESIGN OF THE REAR AXLE SHAFT
REAR AXLE PRODUCTION UNIT
FINISHINGMACHINE16. CHECK CRACK ONREAR AXLE SHAFTMAGNA FLUXCRACKDETECTOR1.
FREE FROMCRACKS17. FINALINSPECTION OFSHAFT REAR AXLESTAGE 2.
AS PER PARTPRINTSPECIFICATION2(132 JPS)
8.4 OPERATIONS PERFORMED
FINISH TURN SHAFT REAR AXLE AND CUT THREADS
MACHINE TYPE - NCL-15;NCL-16
CUTTING PARAMETERS:-
TOOL NO FEED SPEED
06 0.016”/0.20” 750ft/mtr
07 0.006”/0.12” 750ft/mtr
0101 0.0787/RN 650ft/mtr04
04 0.012”/RN 700ft/mtr
GAUGE USED
1. G-303272.
2. G-85004/23.
3. G-304054.
4. G-85004/15.
5. G-303296.
6. G-303277.
7. G-303458
8. G-303434
8.5 TESTING SHAFT RUNOUT CHECKING AFTER CNC
OPERATER’S PROCEDURE(BENCH CENTRE)
1. MOUNT THE COMPONENT ON CENTRE
2. SHAFT SHOULD BE ALLIGN WITH CENTRE
3. CHECK THE SHAFT FOR ROTATION ON THE CENTRES.
4. MOUNT THE DIAL GAUGE ON THE TABLE & CHECK THE
RUNOUT.
5. CHECK THE RUNOUT & IF CHANGE IN DIMENSION, THEN CHECK
THE FEED ON THEMACHINE.
TO DRILL AND REAM 8 BOLT HOLES ON FLANGE
TO DRILL AND REAM 8 BOLT HOLES ON FLANGE
DRILL TWO MANUFACTURING HOLES.
DRILLS USED :- 4235AA-ET-85A
HOLE MILLS :- 4235AA ET 86A
:- 4235AA EG 27
:- 7235 AA EG 4
LIMIT GAUGES :- G-40088G-40087
Figure 22: DRILL AND REAM 8 BOLT HOLES ON FLANGE
8.6 OIL GROOVE ON STEM END FACE
CUTTER USED :- FM CUTTER 4235 AET 5
CUTTING SPEED :- 800 RPM
FEED:- BY HAND
GAUGE TO CHECK:- 4235 AEG 6
CHAMFER ON 8 HOLES
Figure 23: OIL GROOVE ON STEM END FACE
CHAMFER SIZE :- .070+ 0.10”X45
CHECKING FREQUENCY :- 1/160
TOOL USED :- TS COUNTERSUNK CUTTER DIA 3/4X90
8.7FINISH MILL 38 & 47 INVOLUTE SPLINES
Figure 24: FINISH MILL 38 & 47 INVOLUTE SPLINES
8.8 TOOL & M/C SETTINGS
CUTTER :- 4235A ET 83(FOR 47 SPLINE)
REEMER :- 4235A-ET 9(FOR 38 SPLINES)
FACE CENTRE :- 4235AA EF 44/1
TAIL STOCK CENTRE :- MA-321/25
GAUGES USED :- 4235 EG 714235 AEG 294235 AEG 284235 AEG 72
SPEED :- 180 RPM
FEED :- 400M/MIN
8.9 SHAFT INDUCTION HARDENING:-
QUENCH PRESSURE = 5-7.5 Kg/cu.cm
QUENCH TEMPERATURE = 25C-45C
GAP = 0.085”/.110”
Figure 25: SHAFT INDUCTION HARDENING
8.10 TEMPER INDUCTION HARDENING OF SHAFT
FURNACE TEMPERATURE 230C-240C
TIME PERIOD 1.5-2.5 HRS
CHARACTERISTICS CHANGE OF BASE COLOUR TO GOLDEN
COLOUR
Figure 26: TEMPER INDUCTION HARDENING OF SHAFT
8.11 GRIND SEAL DIAMETER
GRINDING WHEEL :- 4235 AET 87
CENTRE :- MT-5(2 NOS)
DRESSING DIAMOND :- MA 902/37
Figure 27: GRIND SEAL DIAMETER
CENTRE :- MT-5(2 NOS)
DRESSING DIAMOND :- MA 902/37
FINISH GRIND SEAL DIAMETER
TAPER CUT GRINDING WHEEL :- 100/68X40X31.75
SUPER FINISH SEAL DIA :- 2.105”/2
STONE USED :- &nbs