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

CERTIFICATE

This is to certify that this summer training report has been

prepared by HEMAPRASATH (B.TECH-MECH) from SRM

UNIVERSITY , CHENNAI in the partial fulfilment of the

requirement of vocational training at SCOOTERS INDIA

LIMITED, LUCKNOW.

Thematter was analysed by candidate under my guidance and

this report embodies thework doneby him

We wish him a bright future

Guide

Ishwar Prasad

Manager

Machine shop line-2

Scooters India LTD

Lucknow

ACKNOWLEDGEMENT

At this very outset I sincerely acknowledge withgratitude the guidance and support rendered to me byTraining Centre and Machine Shop Department ofScooters India LTD without which this training wouldnot have materialized

I would like to thank Mr S.B.SINGH (H.R. SCOOTERSINDIA LIMITED) for providing me an opportunity tointeract and take guidance from engineers of Machineshop department.

During my summer training at Machine Shop I felt likea family member and learn a lot about how a teamworks to achieve the target, how industry workstowards continuous improvement in the direction ofthe cost efficient, quality, customer satisfaction andsociety at large.

I would like to thank Mr.IswarPrasad(Dy.Manager,Machine Shop), and all engineers, staffand workers of machine shop department, forproviding me proper guidance , site visiting , help andother facilities makes my summer training veryinteresting and easier.

Preface

Summer Training plays an important role inengineering course as it give practical knowledgeof the things that we study theoretically in ourcourse.

It is my great pleasure in presenting the reporton manufacturing of Rear Wheel Drum andsuggests improvements based on observationalmade at various stages of manufacturing, by thelearned fellow and faculty members of ScootersIndia LTD, Lucknow

It also gives knowledge about total productionprocess and quality management and howengineers work to utilize the resources properlyand efficiently

PRODUCT PROFILE

ASSEMBLY:

Thecomponentsmanufacturedintheplant aswell asthoseboughthavetobefinallyassembledtomaketheproduct three wheelers. In the process many sub-assemblies too are involved. However, two main

assembliesworthmentioningare engine

assembly and vehicle assembly. Both areconveyorised. Every 5 mins a three wheelers rollsdown the conveyor. The vehicle conveyor has 23stations. Speed canbe adjusted tomeet increasingdemand.

DICASTING:

Thebiggestdiecastingshopinthispartof thecountryhandles bothAluminiumandZinc alloys. Equippedwithpressure die casting machines of 160,250,400 and1000 tons locking pressure, the metal is fed tomachinesfromindividualholdingfurnaceof75/150kg,

Aluminiumcapacity.

The shop based on projected area, is capable ofproducing aluminiumdie casting upto5 kg inweight.Theshopisbackedbychemicalsandmetallurgical labsas also with a die maintenance section. The well-equipped machineries are used in two shifts thatproduce all the accessories required by thisorganization. The die casting of various types ofcomponents like Gear box housing, Crankcase, Frontwheel drum, rear wheel drum, Bell housing, Magnetoflange,Cylinderhead,LowerandUpperhandlebar ,

Levers, Differential housing cover, Brake shoe areundertaken.

Die casting components for fulfilling customersrequirementarealsotakenup.Someofourcustomersare BHEL, Bhopal, Greaves India Limited, Aurangabadto whom supplying the Gear boxes and 422 cc

aluminiumEnginesaresupplied.

MACHINE SHOP:

Machine shop has a wide variety of machines likeGeneral purposemachine, Special purposemachines,Multi-purpose machines, Multi-spindle automatic

machines, Single spindle automatic machines etc.,which is mainly working onsingle shift thougheightdifferent lines. Line no. 2 is basically machining theAluminium components. Crankshaft and Cylindermachining is usually doneonLineno. 3, Lineno. 4 isthegrinding linewhere thegrindingprocess is done.Heat treatment is performed in Line no. 5, whiledifferent turning of shafts and gear shaping andshaving are carriedonLineno. 6 and7includes thefunctioning of gear manufacturing process mainlybroaching,hobbing, finishing, turning,gearshavingetc.Machining of different levers, centre less grinding oftubes&shafts, threadrollingoperations isachievedinLineno.9.Blankturningofgear&machiningofparts

Is done on multi-spindle & singlespindle automaticmachine. Engine

components &some vehicle components are primeproductions.

FABRICATION:

The fabrication operations are carried out in twodepartment wise. Press shop &welding shop. Thepress shopis equippedwith20presses rangingfrom

10tonnes to550tones.Pressesarefedbysheets cuttosizeonshearingmachinesof3000×6&2500×3mmsize.Componentsrangingfromwasher tocabinroof&door (1000×1200mm) are being processed in thisshop.

The welding shop is equipped with battery of spotwelding, MIG welding, Samwelding & arc weldingmachines. CO2welding is extensivelyusedfor gettingclose toleranceonweldedstructure. Thedepartmenthas its ownauxiliary shopfor maintenancefor tool &die.

SURFACE TREATEMENT & PAINTING:

Paintshopincludesthreesectionnamelypaintsection,spray phosphate section, pickling. Paints section

includes two conventions painting &spray booths &one electrostatic painting plant. The 1st one is calledconventional primepaintingareBulow230 spraygun&pressurefit tanks. Thevarious types of frames likediesel 750, mini petrol, mini diesel, diesel floormounting, diesel Nepal, diesel scrubber, electricvehicle are painted here. The conventional booth isknownas conventional finishbooth. Here the frameaccessories likecabinfront, roof top, front frock, axlehousing is painted. In electrostatic plant theaccessories of the frame, the component of lighterweight andminimumsizelikesilencer, pillar &variousbracketsarepaintedhere.

In spray phosphating the main is to clean thecomponent before painting or to make surfaceaccordingtopaint requirement. After phosphatingthe

productsgoestopassivationfor convertingferroustoferric for painting needed. The products come fromwelding shop, press shop & machine shop tophosphating&after theprocess is beinggonetothevehicleassembly.

FOUNDRY:

Thefoundry,mostmoderninthis part of thecountry,canproduceall gradesofgreycast ironaswell asSGiron.Infact, ithadbeeninnovativetofindnewprocessofmodulation, for whichit was grantedtwopatterns.Equipped with an induction melting furnace, shellmoulding machine & core scooter, green sandfacilities, isothermalheat treatment furnace,onesandMuller machine, two shat blasting equipment, itsnormal rangeof productionweight is upto8 kgonapatternplateof450×600mm.

The foundry is not fully loaded with its captiverequirements. Sparecapacity is utilisedfor producingsophisticated casting of prestigious customer likeBHEL, Indianrailways, aerospace, brakes Indialimited,Cromptongreaveslimited.

Thetwotypeofmouldingisdonehere.Sandmoulding&GreenMoulding.Thefoundrycanmanufactureawiderangeof products namely Crankcase flange, Magnetomotor, Engine output flange, adapted plate forelectricalvehicle.

TOOL ROOM:

The tool roomis a cell where brain combines withversatility to evoke the new era of invention. Thedesigns of tool coming from main tool planningdepartment are implementedhere. The tool roomisfurnishedwithwell-equippedmachineriesnamely- CNCmachine (Taiwan), J ig Boring machine (Czechrepublic), J ig grindingmachine (Switzerland), ProfileGrinding machine (Germany), Die sliding machine(Czechrepublic),EDM(USA).

Tool roomevokeahighperformanceoutput consistingalmost 99.9% of company’s requirement : One diecasting dieper year, 1-10 press tool per month, 8-10jigs per month, 10-12 gauges per month&400 C.T.toolspermonths.

These machines areefficiently used tomanufacturing differenttools & dies like jigs &

fixtures, Gauges, Cutting tools, Forging dies, Diecasting dies, Developments Items etc. The differentactivities like Turning, Milling different shapes,Grinding, Heat treatment, J ig boring, J ig Grinding,checking in the standard room, heat treatmentaccording tothejobrequirement, final inspectionareundertakenintheinthetoolroom.

DESIGN & DEVELOPMENT:

Design&Developmenthasbecometheprimeover theorigination.Thebusinesstodayiscustomerdriven.Thedepartmentremainsinconstanttouchwiththecustomer totransplanttheirneeds&thinkingonthedrawingboardonthecomputerscreen.Thedepartmentservestheinternalcustomersthroughdesigndevelopment&standardisation.EquippedwithCADLAB,Advancedinstrumentation,TestingRingPrototypemanufacturingfacilities&theinternet.ThecompaniesDNDarerecognisedbytheMinisterofScience&Technology,GovernmentofINDIA.Ithasthedistinctionofthedeveloping1stZeropollutionelectricthreewheeler intheworld.

COMPUTER AIDED DESIGENEDLABORATORYIES:

CADLaboratoriesprovidesawiderangeoffacilities.Theversatilityofbrainscombineswithaflavourofnewcreationtoevolveaqualityproduct.All thedesigning&draftingProcessmouldintoashapeinthiswell-equippedenvironmentofCADlaboratory.ThisincludesFEanalysis,workingmodelsimulation&designingthroughAUTOCAD14.

COMPONENTS:

Back Plate:

The Back Plate serves as the base onwhichall thecomponentsareassembled.Itattachestotheaxleandforms a solid surface for the wheel cylinder, brakeshoes andassortedhardware. Since all the braking

REAR WHEEL DRUM

operationexerts pressureonthebackplate, it needstobeverystrongandwearresistant.

Leavers for Emergency or parking brakes andautomatic brake shoe adjuster were also added inrecentyears.

Brake Drum:

TheBrakeDrumisgenerallymadeofaspecial typeofcast iron which is heat conductive and wearsresistance. It is positioned very close to the brakeshoewithout actually touchingit, androtateswiththewheelandaxle.

Wheel Cylinder:

Onewheelcylinder isusedforeachwheel.Twopistonsoperate the shoes, one at each end of the wheel

cylinder.Whenhydraulicpressurefro

mthemaster cylinder acts uponthepistoncup, thepistonsare

Pushedtowards the shoes, forcing themagainst thedrum.

Brake Shoe:

Brakeshoesaretypicallymadeof twopiecesof sheetsteel weldedtogether. The frictionmaterial is eitherrivetedtotheliningtableorattachedwithadhesive.

Automatic Self –Adjuster:

The self-adjuster is used to adjust the distance

betweenthebrakeshoeandthedrumautomaticallyasbrakeshoeswear.

PHOTOS OF REAR WHEEL DRUMWHILE MANUFACTURING AND ITSMACHINE:

STEPS INVOLVED IN MANUFACTURINGOF R.W.DRUM

1. IN DIE CASTING SHOP:Machinethat isusedindiecasting shopis “HMTBULLET 250Ton” adnois10041.

250Tonis thelockingpressureappliedduring themanufacturingofR.W.Drum.

Cast ironandsteel hubis usedformanufacturingof outer circular ring and inner circular ringrespectively.

DICOAT WATERWASTE AND DICOAT

40(unchidova) is used to prevent sticking thematerial tothedie.

Molten Aluminum alloy is used for itsmanufacturingwhosemeltingpointisnearly

600°c, but in die casting shop it is heated up to642°c.

Design provided in this structure so that it canabsorbtheexcessloadanddoesn’tgetaffected.

Pressure die casting is used for the wholemanufacturing, twotypesofdieisusedoneisfixedandoneismoving.

Timelimits:

Timeformovingofpiston: 14sec

Lockopentime: 12sec

Standardtime: 15sec

Total standard time taken inmanufacturing of anR.W.Drumindiecastingshopis21sec.