MUTHA ENGINEERING PVT.LTD.

UNIT –I,OLD MIDC SATARA-415004

SUBJECT: PROJECT REPORT

Name : Mrs. Rupali Sachin Dixit

Qualification : Msc (physics)
Collage Name : Y.C.I.S.Satara.
Project : Bajaj 3 wheeleer Break Drum Process Analysis
 PROJECT NAME

Bajaj 3 wheeleer Break Drum Process

Analysis
INPUT PROCESS TURNING OPERATION
 INPUT PROCESS TURNING OPERATION

INPUT-PROCESS-OUTPUT SHEET
Part Operation
Model Part No. Part Name Operation No. Opn. Rev.
Mod. No. Description
3 Wheeler 22151106 Brake Drum Cast Iron 4 170 Boring & Facing 01' 04.09.2019
PRO
CESS

CLAMPING

RESTING
 TURNING OPERATION SEQUENCE METHOD

3M - METHOD

3.1 -OPERATION SEQUENCE

SR. N Activity Cycle sequence Time in Sec

1 Open Door 2
Unloading
2 Press foot switch & Unload component 2

3 Clean Jaw & Resting face Cleaning 5

4 Load component & press foot switch 5

5 close door Loading 2

6 Press cycle start 2

7 Machining cycle Machining 42

CYCLE TIME 60
 AFTER TURNING OPERATION
INPUT-PROCESS-OUTPUT SHEET
Part Operation Operation
Model Part No. Part Name Opn. Rev.
Mod. No. No. Description
Boring &
3 Wheeler 2.2E+07 Brake Drum Cast Iron 4 170 01' 04.09.201
Facing
OUTP
UT
 AFTER TURNING MEASURING METHOD

OUTPUT CONDITION
SR.N Inspection Responsibil
Parameter Defect No. Specification Measured by Gauge No.
O. frequency ity
1 Inner Dia 44,45,46 52.00 +0.050 Plug Gauge ……….. 100%
Surface Finish on
2 41 Ra 6.3 Surface Tester ……….. 1 per Shift Inspector/
dia.52.0 Operator/
3 Inner Dia 52,53 90.0 +1.0 Paddle Gauge ……….. 1 per 20 CMM
Engineer
54,55,56,
5 Thickness 5.0 ±0.10 Snap Gauge ……….. 1 per 20
57
Dent, damage, free No Dent, damage,
6 from burr & - Visual ……….. 100% Operator
burr & patchmark
patchmark
 INPUT PROCESS FINISH BORE OPERATION
INPUT-PROCESS-OUTPUT SHEET
Part
Model Part No. Part Name Mod. Operation No. Operation Description Opn. Rev.
No.
3 Wheeler 22151106 Brake Drum Cast Iron 4 180 Boring & Facing 01' 04.09.201

PROCESS
 FINISH BORE OPERATION METHOD
3M - METHOD

3.1 -OPERATION SEQUENCE

SR. N Activity Cycle sequence Time in Sec

1 Open Door 10
Uploading
2 Press foot switch & Unload component 10

3 Clean Jaw & Resting face Cleaning 10

4 Load component & press foot switch 5

5 Press foot switch & Center clamp 5

Loading
6 close door 5

7 Press cycle start 5

8 Machining cycle Machining 42

CYCLE TIME 92
AFTER FINISH BORE OPERATION
 FINISH BORE OPERATION INSPECTION
PARAMETERS
OUTPUT CONDITION

SR.NO Defect Inspection

Parameter Specification Measured by Gauge No. Responsibility
. No. frequency

1 Inner Dia 59,60 170.00 Paddle Gauge ……….. 1 per 20

+0.10
2 Depth 68,69 31.00 ±0.20 Flush Pin Gauge ……….. 1 per 20

Cylinder Bore Inspector/

3 Ovality max. 66 0.10 mm ……….. 1 per Shift Operator/ CMM
Gauge
TIR Gauge / 1 per 20 / Engineer
4 Total Runout 58 0.06 mm Mahar ……….. (Mahr)1 Per
Roundness Shift
5 Face Runout 43 0.10 mm Dial Gauge ……….. 1 per 20

6 Radius - R1 Radius Gauge ……….. 1 per 20 Inspector

Surface Finish
7 67 Ra 6.3 Surface Tester ……….. 1 per Shift Inspector
on dia. 170.0
Dent, No Dent,
8 damage, free - damage, burr Visual ……….. 100% Operator
from burr & & patchmark
patchmark
 INPUT PROCESS OF DRILLING TAPPING

INPUT-PROCESS-OUTPUT SHEET
Part
Model Part No. Part Name Mod. Operation No. Operation Descriptio Opn. Rev.

Brake Drum Cast No.

3 Wheeler 2.2E+07 4 190 6 Hole Drilling 01' 04.09.2019
Iron
PROCESS

LOCATING RESTING
(ID 52.0)
 DRILLING TAPPING OPERATION METHOD

3M - METHOD

3.1 -OPERATION SEQUENCE

SR. NO. Activity Cycle sequence Time in Sec

2 Unload component . Unloading 5

3 clean Resting face. Cleaning 10

4 Load part on fixture. Loading 5

5 Press cycle start button. 5

8 Machining cycle Machining 32

CYCLE TIME 57
 DRILLING TAPPING MEASURING
PARAMETERS

3.2 PROCESS PARAMETERS

Sr. Defect No. Cutting Insert / Drill Operation Cutting Feed in mm/min. Make
No. Tool Detail speed in
74,75,76, HSS Drill dia. 13.0 4 Hole Drilling Dia
1 Step Drill 649 192mm/min. SMITH
81,82 x 11.5 11.50
74,75,76, Counter HSS Drill dia. 9.0 2 Counter Drilling
2 649 192mm/min. SMITH
81,82 Step Drill x 4.70 x 90º Dia 4.70
 AFTER DRILLING TAPPING

INPUT-PROCESS-OUTPUT SHEET
Part Operation
Model Part No. Part Name Mod. Operation Descriptio Opn. Rev.
No.
No.
3 Wheeler 22151106 Brake Drum Cast Iron 4 190 6 Hole Drilling 01' 04.09.2019

OUTPUT
 DRILLING TAPPING MEASURING
PARAMETERS
OUTPUT CONDITION
Inspection Responsibilit
SR.NO. Parameter Defect No. Specification Measured by Gauge No.
frequency y
Dia 11.50+0.2
1 Hole dia. 74,75 Plug gauge ……….. 1 per 20
x4nos.
Dia 4.7+0.1
2 Hole dia. 81,82 Plug gauge ……….. 1 per 20
x2nos.

3 Counter 70,71 Dia 9 x 90° +0.1 Vernier Caliper ……….. 1 per 20

Inspector/
Counter Operator/
4 - 2.70 ±0.20 Flush pin Gauge ……….. 1 per 20 CMM
depth
Engineer
Angle
5 between 90°±0.30' Relation Gauge ……….. 1 per 20
two drill
Angle
6 between 45°±0.30' Relation Gauge ……….. 1 per 20
drill Dia
7 PCD 77,78,79 Dia 70.0±0.10 Relation Gauge ……….. 1 per 20
Dent, No Dent,
8 damage, - Visual ……….. 100% Operator
damage, burr
free from
TAPPING OPERATION
 AFTER TAPPING OPERATION
INPUT-PROCESS-OUTPUT SHEET
Part Operation
Model Part No. Part Name Mod. Operation Descriptio Opn. Rev.
No.
No.
3 Wheeler ######## Brake Drum Cast Iron 4 200 2 Hole Drill Tap 01' 04.09.2019

OUTPUT
 TAPPING OPERATION INSPECTION
PARAMETERS

OUTPUT CONDITION

SR.N Paramete Inspection

Defect No. Specification Measured by Gauge No. Responsibility
O. r frequency
Ø5.00±0.1- 2
1 Hole dia. Plug gauge ……….. 1 per 20
Hole
M6 x 1.0 mm - 2 Thread Plug Inspector/ Operator/
2 Tapping ……….. 1 per 20
Hole gauge CMM Engineer
Relation 1 per
3 PCD Ø 66.0±0.1 ………..
Gauge/CMM 20/1/Shift
Dent,
damage, No Dent,
4 Visual ……….. 100% Operator
free from damage, burr
burr
 GROOVING OPERATION PROCESS
INPUT-PROCESS-OUTPUT SHEET
Part
Model Part No. Part Name Mod. Operation No. Operation Descripti Opn. R
No.
Face Grooving
3 Wheeler 2.2E+07 Brake Drum Cast Iron 4 210 01' 04.0
& Chamfering
PROCESS

CLAMPING

RESTING
LOCATING(ID
 GROOVING OPERATION SEQUENCE
METHOD
3M - METHOD

3.1 -OPERATION SEQUENCE

SR. NO Activity Cycle sequence Time in Sec

2 Press foot switch & Unload component Unloading 5

3 Clean Locator & Resting face . Cleaning 10

4 Load component with clamp plate. 10

5 Press foot switch for Center clamping. Loading 10

7 Press cycle start 10

8 Machining cycle Machining 90

CYCLE TIME 135

 GROOVING OPERATION MESURING
PARAMETERS
3.2 PROCESS PARAMETERS
Sr. Defect Cutting Cutting Feed in
Tool Detail Operation speed in Make
No. No. Tool mm/min.
m/min.
1 85,89 Brazed Tool BRZ TOOL ISO7 RH 2516 5.5MM Grooving 80 R.P.M 24 mm/min. ASHOK
2 85,89 Brazed Tool BRZ TOOL ISO 2 LH 2020 45˚ K 20 Chamfering 182.0 x 45 Deg 80 R.P.M 24 mm/min. ASHOK

3 85,89 Brazed Tool BRZ TOOL CHAMFER BT45X8X60 R/H Chamfering 0.5 x 45 Deg 80 R.P.M 24 mm/min. ASHOK

3.3 PROCESS CONDITION

METH Hydraulic clamping pressure in Pressure M/c

91 15-25 kg /cm2 Daily JH
OD Kg/cm2 gauge operator

TOOLI Cleanliness of part resting & Finish & clean By hand / M/c
………… Daily JH
NG clamping surfaces Resting Face visual operator
 AFTER OPERATION
INPUT-PROCESS-OUTPUT SHEET
Part
Model Part No. Part Name Mod. Operation No. Operation Description Opn. Rev.
No.
Face Grooving &
3 Wheeler 22151106 Brake Drum Cast Iron 4 210 01' 04.09.2019
Chamfering
OUTPUT
 AFTER TAPPING OPERATION INSPECTION
PARAMETERS
OUTPUT CONDITION
SR.N Inspection Responsibilit
Parameter Defect No. Specification Measured by Gauge No.
O. frequency y
Dia 202.0 ±
1 Groove ID Paddle Gauge ……….. 1 per 20
0.20
Dia 192.0 ±
2 Groove OD Paddle Gauge ……….. 1 per 20
0.20

3 Depth 14.0±0.2 Flush pin Gauge ……….. 1 per 20

Inspector/
Operator
4 Radius R 0.5 Visual ……….. Every tool change.

Chamfer
5 182.0 +1.0 Vernier Caliper ……….. 1 per 20
dia.
Groove
6 Chamfer 0.5x45' Visual ……….. 1 per 20
dia.
Bevel Protector/Std.
7 Angle 45°±30' ……….. 2 Per Shift Operator
Template
Dent, damage, No Dent,
8 free from burr damage, burr & Visual ……….. 100%
& patchmark patchmark
THANK YOU