SUMMER TRAINING PROJECT REPORT

ESCORTS INDIA PVT. LTD. AGRI MACINERY GROUP ,

FARIDABAD

STUDY OF ENGINE/CYLINDER BLOCK MACHINING OF

TRACTOR

UNDER GUIDANCE OF :-
Mr. VIJAY RAM

PREPARED BY :-
ABHIJEET SHARMA
B.tech – Mechanical Engg.
B.S.A.I.T.M. , Faridabad
 PREFACE

Industrial exposure is the most crucial part of the technical

studies in which a student is able to synchronize his technical
knowledge with practical knowledge gained in any of the
organization in which he gets his training from. I was allotted
a project titled, “Making of ENGINE/CYLINDER Block or either
it is called Transmission Line, in ESCORTS INDIA PVT. LTD.,
FARMTRAC DIVISION”.
I hope that the word of my project communicates the actual
experience gained with subtlety & precision, which is
unapproachable, by any other means. From the medium of
this project report, I would like to thank each and every
honourable employee of ESCORTS INDIA PVT. LTD.
FARMTRAC DIVISION, who has helped me to gain all the
knowledge in the respective production shop, where
production process was involved.
 COMPANY PROFILE

ABOUT THE COMPANY

The escorts group is among India’s leading engineering
conglomerates operating in the high growth sectors of agri-
machinery, construction & material handling equipment,
railway equipment and auto components.
Having pioneered farm mechanization in the country, Escorts
has played a pivotal role in the agricultural growth of India
for over five decades. One of the leading tractor
manufacturers of the country, Escorts offers a
comprehensive range of tractors, more than 45 variants
starting from 25 to 80 HP. Escort, farmtrac and powertrac are
the widely accepted and preferred brands of tractors from
the house of Escorts.
A leading material handling and construction equipment
manufacturer, we manufacture and market a diverse range
of equipment like cranes, loaders, vibratory rollers & forklifts.
Escorts today is the world’s largest pick ‘n’ carry hydraulic
mobile crane manufacturer.
Technological and business collaboration with world leaders
over the years, globally competitive indigenous engineering
capabilities, over 1600 sales and service outlets and
footprints in over 40 countries have been instrumental in
making Escorts the Indian multinational. At a time when the
world is looking at India as an outsourcing destination,
Escorts is rightly placed to be the dependable outsourcing
partner of world’s leading engineering corporations looking
at outsourcing manufacture of engines, transmissions, gears,
hydraulics, implements and attachments to tractors, and
shock absorbers for heavy trailers.
In today’s global market place, Escorts is fast on path of an
internal transformation, which will help it to be a key driver
of manufacturing excellence in the global arena. For this we
are going beyond just adhering to prevailing norms, we are
setting our own standards and relentlessly pursuing them to
achieve our desired benchmarks of excellence.
 OVERVIEW – MATERIAL MANAGEMENT

Presently procuring materials for 80,000 tractors per annum.

Present procurement value over US$ 35 million.
Production will rise to 100,000 tractors per annum in 2 years.
Procurement value will rise to almost US$ 45 million in that
period.
Presently 387 suppliers of which over 95% are India
domestic.
Advantages of low costs of materials in india.
Items procured are:
 Castings
 Forgings
 Machined parts
 Proprietaries
 Sheet metal
 Hardware
 ACKNOWLEDGEMENT

I would like to thank to all those with whom I worked and

whose thoughts and insights helped me increasing my
knowledge and understanding of working in the organization.
I would like to pay my sincere gratitude to Mr. VIJAY RAM
and all employees, my project guide, who helped me during
the course of my training by providing his valuable
suggestion, ideas and guidance which proved beneficial for
completion of my project. Besides I would also thank to all
the supervisors, foreman and workers who helped me to
understand the depth of my project, what they want out of
the project.
In the end I would like to thank the ESCORTS AGRI
MACHINERY GROUP for providing me with this brilliant
opportunity to understand the working of an industry and
developing my technical aptitude.
 TRACTOR MACHINE SHOP ( PLANT – 1 )

The various departments of the tractor machine shop plant-1

are as follows:
1. Gears and Shafts:
The major components manufactured by Gears and
Shafts division are:
 Engine gears
 Transmission gears and shafts
 Differential gears and shafts
 Lever

2. Tool room:
The tool room caters to jig, fixtures, dies manufacturing
etc.
3. Power house:
The power house has generators and compressors of
varying capacities.
4. Heavy castings:
The components manufactured by heavy castings
division are:
 2 cylinder engine block
 3 cylinder engine block
 Gear box housing
 Differential housing
 MISSION
“Escorts Endeavour’s to transform lives in rural and urban
India by leading the revolution in agricultural mechanization,
modernization of automotive and railway technology, as well
as transformation of Indian construction industry”

QUALITY POLICY
We shall strive to continuously improve to meet the ever-
rising expectation of our customers at the lower cost. Each
one of us must fulfil the need of our customer, both internal
and external with the highest degree of commitment thereby
creating a quality organization geared to ensure total
customer satisfaction and the sustained health and
prosperity of our business.
 Study of Cylinder Block Machining
Introduction
Cylinder block of four stroke four cylinder diesel engine is
done after casting. A cast cylinder block is come from vendor.
Machining of cylinder block is done at 10 different machines.
E 3.125/234- it is the machining line of cylinder block. In this
line 4 stroke engine cylinder block is machined. The total
displacement of the engine is 2860 cc.
BSM 1- Block straight milling. This performs in duplex milling
machine. It has two rotating cutting rotor.
Target – To have a rough cutting on sump face and head face.
Depth of cut is 1.5mm on each face. So cutting about 3mm.
Machine – 2
Mazak horizontal – NEXUS 8800 II – In this machine mazatrol
software is used. There is continuous supply of machine ( oil
& water ) to work as coolant and cleaner. CNC machine here
is used for various operation on head and sump face and cap
sheet ( finishing, drilling, counter drill, and tapping ).
Procedure – locate from party dowel and clamp.
Party dowel – TCS ( Tappet cover side ).
Clamp – NPS ( Name plate side ).
Setup – 1
Head face – On the head face there are 18 holes (with
tapping) are produced for tightening the cylinder head. After
that there is 9 more hole procedure for the water passage.
These holes are drilled only. One more hole produced for oil
passage.
Sump face – On the sump face there are two more dowel are
created for further machining process. On sump face there
are 14 more holes are produce.
Setup – 2
With the help of manufactured dowel fixed sump face and
perform on the NPS, TGS, BHS, TCS.
Time gear side – On this face there is 2 holes drilled and one
dowel machined.
Machine – 3
HMC – 25 :- This machine programmed with FANUC CODE.
There are two types of fixtures. Here we use mechanical
rather than hydraulic. To mechanically these fixtures we use
clockwise.
Use crane to hold the job and place on fixture with dowel on
sump face. Now put clockwise and tighten the screw. We use
brake (hydraulic) pedal in order to start/stop. After this
rotation of fixture is done and now door were closed and
change pallet and start the program. On this machine we can
perform all the operations that are done earlier and this
machine check the tool life also. This gives OEE (overall
equipment efficiency) of the tool.
For change the pallet we use this program:

MOI M60 Cycle

EOB Insert
start
On this machine we perform oil gallering. This is done from
crank to cam at 29 degree and from crank to idler at 18
degree. Oil gallery from crank to cam is longer than crank to
idler.
Alternatives of this machine are BD03 (block drill) and
GBD01 (gear block drill-gear box department). In this
machine drilling is done with the help of radial drilling
machine. These drilling machine two fixtures of 29 degree
and 18 degree are made so that drill can be done in straight
manner.
Machine – 4
BSM12 ( Block straight milling ) – On this machine milling and
notching is done at one of the side used as a stopper for
bushes. On this machine cutter have 10 side mill and 5 end
mill.
Machine – 5
BNR04 ( Block nut runner ) – For main bearing cap bolt
tightening first already finished caps are put on the web and
mechanically tightened using BNR.
Machine – 6
Now block again comes on the HMC25 ( Horizontal milling
centre ) for crank, cam and idler boring. Here semi finishing is
done. First rough boring is done and there after semi finished
boring is done. And thereafter it goes to vertical milling
centre.
Machine – 7
VMC26 ( Vertical milling centre ) – At VMC26 tappet boring is
done. Here it create 4 holes of ɸ 25mm dimensions.
Also along these tappets are created 4 cams working. At this
stage checking of all dimensions are done here. For checking
all dimension they use ring gauge, bore dial gauge, go/not go
plug are used.
Machine – 8
BSB14 ( Block straight boring ) – 2 way boring. Here boring of
crank, cam and idler is being finished. Boring is done from
both end since it is two way. In this machine boring of
crank/cam is done from one side and boring of idler from
another side.
Machine – 9
BWT4 ( Block washing machine ) – This is a washing machine
with both type of block air and block water cleaning. And
final inspection is done over here.
Machine – 10
BBP ( Block bush pressing ) – For this purpose BEMCO
hydraulic press is used. This is used to put bush inside the
cam hole.
Capacity – 25 kw.
 Conclusion
Summer training in ESCORTS LTD. really helped me to
familiarize myself to the practical knowledge of industrial
production processes. The whole training period was very
interesting, instructive and challenging. Through this training
I was able to gain new insights and more comprehensive
understanding about the real industry working condition and
condition.
I got the idea of working of automatic CNC machines,
different processes used in machining of cylinder block. All of
this valuable experience and knowledge that I have gained
were not only acquired through the direct involvement in
task given but also through other aspect of the training such
as work observations, interaction with operators, supervisor
and other people involved in the process.
It was a good idea and good chance to expose to the work
environment that we will have to face and practice after we
graduate. As a result of the training now I am more confident
to enter the employment world and build my future career.
There are several types of processes which are used in
cylinder block machining which are performed in
different machines:-
1. Facing & centering.
2. Rough turning.
3. Finish turning.
4. Drilling.
5. Hobbing.
6. Inspection.
 Facing & Centering
Facing is part of the turning process. It involves moving the
cutting tool at right angles to the axis of rotation of the
rotating work piece. This can be performed by the operation
of the cross-slide, if one is fitted, as distinct from the
longitudinal feed (turning). It is frequently the first operation
performed in the production of the work piece, and often the
last- hence the phrase "ending up".
 Tooling element :-STD Self Centering ViceTGR-F-3951
PADS
 Swiveling Stopper
 Cutting Tool Details :-STD Centre Drill DIA 5/16 inch STD
Face Mill Cutter
 Speed :-Centre Drill -1000rpmFace Mill Cutter -139rpm
 Cutting Time:- 1.5 min
 Tool Life:- Centre Drill 500 componentsFace Mill Cutter
100 components
 Gauge Details:- STD Height gauge (0-500)TGR-G-9120
Centre Depth Checking Gauge 5.20/5.0
 Rough turning
When a great deal of stock is to be removed, you should take
heavy cuts to complete the job in the least possible time. This
is called rough turning. Select the proper tool for taking a
heavy chip. The speed of the work and the amount of feed of
the tool should be as great as the tool will stand. When you
take a roughing cut on steel, cast iron, or any other metal
that has a scale on its surface , be sure to set the tool deep
enough to get under the scale in the first cut. Unless you do,
the scale on the metal will dull or break the point of the tool.
Rough machine the work to almost the finished size; then
take careful measurements.
 Tooling element:- clamping jaws MAS-317/24
 Indexing plate MAS-317/9
 Tool holder L-170-5-3225
 Tool change frequency:- 200 pcs per edge
 Feed :-0.28 mm/rev
 Spindle speed :-800 rpm
 Gauge details :-STD SNAP gauge 51.00±0.15
 DIAL indicator L.C 0.01
 Finish turning
When you have rough turned the work to within about 1/32
inch of the finished size, take a finishing cut. A fine feed, the
proper lubricant, and, above all, a keen-edged tool is
necessary to produce a smooth finish. Measure carefully to
be sure you are machining the work to the proper dimension.
Stop the lathe when you take measurements if you must
finish the work to close tolerances, be sure the work is not
hot when you take the finish cut. If you turn the work piece
to exact size when it is hot, it will be undersize when it has
cooled.
 Tooling element :-Soft Jaws TGR-F-9114
 Cutting Tool Details :STD T-Max Tool Holder PDJNL-2525
 Speed :-750rpm
 Feed :-0.2mm/min
 Cutting Time:- 3.2 min
 Tool Life:- 500 components
 Gauge Details:- STD SNAP gauge
 DIA 59.69/59.45
 Drilling
Drilling is a cutting process that uses a drill bit to cut or enlarge
a hole in solid materials. The drill bit is a multipoint, end
cutting tool. It cuts by applying pressure and rotation to the
work piece, which forms chips at the cutting edge.
 Machine name :-Radial drill machine
 Tooling element :-quick change chuck and sleeve
 Cutting tool :-HSS drill dia 11.5 mm
 Counter drill dia 13 mm
 Tap ½ 20 UNF-2B
 Reamer H11
 Cutting speed :-HSS drill 580 rpm
 Counter drill 300 rpm
 Tap 180 rpm
 Reamer 180 rpm
 Feed :-HSS drill 0.2mm/rev
 Counter drill 0.2mm/rev
 Gauge Details :-STD Threading gauge
 GO , NO GO for ½ 20 UNF-2B thread
 Hobbing
Hobbing uses a hobbing machine with two non-parallel
spindles, one mounted with a blank work piece and the other
with the hob. The angle between the hob's spindle and
the work piece's spindle varies ,depending on the type of
product being produced. For example, if a spur gear is being
produced, then the hob is angled equal to the helix angle of
the hob; if a helical gear is being produced then the angle
must be increase by the same amount as the helix angle
of the helical gear. The two shafts are rotated at a
proportional ratio, which determines the number of teeth on
the blank; for example, if the gear ratio is 40:1 the hob
rotates 40 times to each turn of the blank, which produces 40
teeth in the blank.
 Tooling Element :-Job Carrier
 Cutting Tool Details :-HOB Cutter
 Gauge Details:- OUTSIDE MICROMETER 50-75 mm
 L.C- 0.01
 DIAL indicator L.C 0.01
 Inspection

Inspection is the last stage of manufacturing. It is done

manually to check for defects and other irregularities.
 B.S. Anangpuria Institute of Technology
&
Management

Submitted by :- Submitted to :-
Abhijeet Sharma Mr. Brijesh kumar
15/ME001
M.E. – 1(4.1)
B.S.A.I.T.M.
Summer Training Project Report

Topic :- Study of engine/cylinder

block machining

Escorts Pvt. Ltd.

Agri Machinery Group