TRAINING REPORT Escort Tractors

Chitkara Institute of Engineering & Technology - Rajpura
1 | P a g e a n m o l r a t t a n / ME / 7
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TRAINING REPORT

OF

SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN

AT

IN

AGRI MACHINERY

ON

SHEET METAL AND HYDRAULLIC COMPONENTS

SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY

IN

DEPARTMENT OF MECHANICAL ENGINEERING

Submitted By: Under the Guidance of:
Name: Anmol Rattan Name:
College Roll No.:E104132 Designation:
University Roll No.:1182316 Departments:

CHANDIGARH-PATIALA NATIONAL HIGHWAY,
VILL.JHANSLA, TEHSIL, RAJPURA,
DISTT. PATIALA 140401
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ACKNOWLEDGEMENT

I would like to thank to all those with whom I worked and whose thoughts and insights helped
me in increasing my knowledge and understanding of working in the organization. I would like
to pay my sincere gratitude to MR. ASHOK KUMAR & 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. These people made me comfortable to understand the
functioning of each machine & about the operation occuring on the machines. They tried their
best to make me understand about the fixtures, tools and gauges used on the machine. These
peoples never made me feel as a trainee in the department rather provide an atmosphere like a
family and feel proud being the part of their through for short while. Without their help this
project would never have taken its present form. In fact this project is the result of their vision,
optimistic and encouraging attitude.

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

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PREFACE

The world is shrinking. New era is going to be an era of great technology and only those
Engineers who will have the ability to move along with fast paced technology are going to
survive. To move along with technology an Engineer must be equipped with the practical
knowledge of work. Now the quality of knowledge is more important than the quantity. So a
person without practical knowledge is nil no matter how many books he has studied.

The practical training is highly conducive for the development of
Solid foundation of knowledge and personality
Confidence
Excellence and Self-discipline

It was my pleasure that I got an opportunity to undergo my six weeks industrial training
in THE ESCORTS GROUP, MATHURA ROAD, FARIDABAD. When I joined ESCORTS,
I was associated with the AGRI MACHINERY under sheet metal components and hydraulic
components department for the six months training period.

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CONTEXT
S.NO. TOPIC PAGE
NO
I. Company Profile
II. Introduction to Assigned Job
II.1 OVERVIEW-manufacturing
II.2 OVERVIEW-material management
II.3 OVERVIEW-training and
development centre

II.4 Knowledge management center
III. Modular description of Assigned Job
III.1 Sheet metal component
III.2 Hydraulic component
IV. Detailed analysis of individual module
IV.1 Tractor configuration
IV.2 Engine and fuel
IV.3 Farmtrac
IV.4 Powertrac
IV.5 Components used in assigned job
V. Project undertaken
V.1 Method involved in production of
rear axle

V.2 Method involved In production of
shaft hydraulic left arm

VI. Industry application
VI.1 Agricultural applications
VI.2 Non-agricultural applications
VII. Conclusion
VIII. Bibliography and references

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I.COMPANY PROFILE

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 and forklifts. Escorts
today is the world's largest Pick 'n' Carry Hydraulic Mobile Crane manufacturer.

In the auto components segment, Escorts is a leading manufacturer of auto suspension products
including shock absorbers and telescopic front forks. Over the years, with continuous
development and improvement in manufacturing technology and design, new reliable products
have been introduced.

Throughout the evolution of Escorts, technology has always been its greatest ally for growth. In
the over six decades of our inception, Escorts has been much more than just being one of India's
largest engineering companies. It has been a harbinger of new technology, a prime mover on the
industrial front, at every stage introducing products and technologies that helped take the country
forward in key growth areas. Over a million tractors and over 16,000 construction and material
handling equipment that have rolled out from the facilities of Escorts, complemented by a highly
satisfied customer base, are testimony to the manufacturing excellence of Escorts. Following the
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globally accepted best manufacturing practices with relentless focus on research and
development, Escorts is today in the league of premier corporate entities in India.

Escorts has been a major player in the railway equipment business in India for nearly five
decades. Our product offering includes brakes, couplers, shock absorbers, rail fastening systems,
composite brake blocks and vulcanized rubber parts.
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 the 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.

\

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II.INTRODUCTION TO THE ASSIGNED JOB

DEPARTMENT: AGRI MACHINERY
FIELDS: 1.Sheet metal components
2. Hydraulic components
3.Production management
PRODUCT: 1.Rear axle
2.Shaft hydraulic lift arm

I.1 OVER VIEW-MANUFACTURING

Escorts - AMG has Tractor manufacturing capacity of 98,940 trs / annum which is the highest in
Asia at one location. Its manufacturing operations are divided in three plants as

Component Plant Tractor Assembly Plant Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings such as Engine blocks,
Gear Box housings, Differential housings are being machined along with Gears &Shafts.
Machine shop consists of State of the Art machines such as CNC Horizontal Machining Centers,
CNC Turning Centers and variety of other precision machines, including Gear Hobbing and
Shaving machines, etc. It is important to note that all critical components are machined in house.

Tractor Assembly Plant is divided into two lines as Farmtrac Line and the Powertrac Line
.
Farmtrac Line is a composite line that has machining as well as assembly activities of Engine,
Transmission & Tractor whereas on Powertrac line only Assembly activities of Engine,
Transnmission & Tractor are being carried out. Tractor Assembly Plant has State of the Art Paint
Shop that has CED paint shop facilities. Engine Shop has State of the Art testing facilities that
includes AVL make Eddy Current Dynamometers in Engine Test House. Crank shaft &
Hydraulic Plant is divided into two parts as Crankshaft Line and Hydraulics Line. Crankshaft
line consists of machine shop where crankshafts of all Tractor models are being machined. It has
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State of the Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line
consists of Machining as well as Assembly activities where critical parts of tractor hydraulics
such as Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has State
of the Art Honing and other precision machines.

II.2 OVER VIEW-MATERIAL MANAGEMENT

Presently procuring materials for 72,000 tractors per annum.. Present procurement value over
US$ 30 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

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II.3 OVERVIEW-TRAINING AND DEVELOPMENT CENTRE

The Escorts Training & Development Centre (ETDC), was established way back in 1969 at
Bangalore to expand the potential of our intellectual capital. Spread over 85 acres of fertile land,
it is a scientifically planned training complex including training halls, model workshops, and
residential cottages and hostels covering 14 acres of land with facilities including canteens,
dining halls, indoor & outdoor recreational areas. Another 76 acres is dedicated to model and
demonstration.

ETDC provides training to farmers, employees, dealers, salesmen, service in-charge, parts in-
charge, mechanics, financial institutions, government nominees, and agricultural & engineering
students. Escorts has till date achieved 3.25 lakh mandays in various training programmes at
ETDC.

ETDC is equipped with modern teaching aids including multimedia, computer learning centre,
training literature in several languages, technical films, slide shows, extensive library for archival
materials on various farming techniques, automobiles, agricultural engineering and management.
There are four sections in which the products of escorts are divided:
Agri machinery (assigned job)
Construction equipment
Auto product
Railway product
The department assigned to me is auto components. Now we will give a brief introduction to all
the sections:

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II.3.1 AGRI MACHINERY
At Escorts Agri Machinery, the catalyst for the next wave of farm mechanization has brought
about two large customer centric initiatives to the fore at Escorts New Products and variants
that are aligned with changing and emerging applications & end usages and the shift of Escorts
from being a standalone tractor manufacturer to being a complete 'Farm Solution' provider.

Agri machinery has further four sections:
Tractors
Crop solutions
Lubricants
Engine & gensets

II.3.2 CONSTRUCTION EQUIPMENTS
Escorts manufacturers and markets a diverse range of construction and material handling
equipment like cranes, loaders, vibratory rollers and forklifts. The company was a pioneer in
introducing the concept of Pick 'n' Carry hydraulic mobile cranes in the 70s in India and
continues to be the world's largest manufacturer of these cranes.

This again has three sub sections under itself:
MATERIAL HANDLING EQUIPMENT

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Pick and Carry cranes
Crawler cranes
Articulated boom cranes
Towe cranes
Forklift trucks
Truck & All Terrain Truck cranes

EARTH MOVING EQUIPMENT

Escort digmax
Escort load max
Backhoe loader (digmax)

ROAD CONSTRUCTION EQUIPMENT

Tandem vibratory compactors
Vibratory soil compactors
Wheel loader
Motor grader

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II.3.3 AUTO PRODUCTS
Escorts Auto Products is the leading manufacturer of auto suspension products including shock
absorbers, struts and telescopic front forks. Our extensive product basket caters to OEMs and
replacement market in India and several other overseas markets for all vehicle categories
including motorcycles, scooters, passenger cars, commercial vehicles, and multi-utility vehicles.
We also design and manufacture specialized dampers and shock absorbers for railway and
defence vehicles. These include following components.
SHOCK ABSORBERS

Shock absorber for two wheelers and three wheelers
Shock absorber for passenger cars & utility vehicles
Shock absorber for commercial vehicles
TELESCOPIC FRONT FORKS

Telescopic front for two wheelers

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McPHERSON STRUTS

Structs for four wheelers
Structs for light commercial vehicles
STEERING COMPONENTS

Steering components for two wheelers
Steering components for three wheeler
SPECIAL DAMPERS

Dampers for railways
Dampers for defence vehicles

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II.3.4 RAILWAY PRODUCTS
Sourcing some of the best technologies from world over, we have worked with the Indian
Railways to pioneer the introduction of products such as Shacku Semi Permanent Coupler, Air
Brakes, and EP Brakes, just to name a few. Developing products of international technological
standards at Indian prices has always been our forte.
To explain further I put forward the sub sections:
BRAKE SYSTEMS
Air Brake System - Passenger - Conventional & Axle Mounted
Air Brake System - Freight - Conventional & Bogie Mounted
Electro Pneumatic Brake System- EMU/MEMU/DEMU
Pneumatic Brake System- EMU- AC/AC
Parking Brake System
Feed Valve for Locomotive
Air Brake Accessories

COUPLERS

AAR H Centre Buffer Coupler - LHB / Main line Coaches
Semi-Permanent Coupler - Schaku Type- EMU/MEMU/DEMU
Automatic Coupler - Kolkata Metro
AAR H Transition Coupler - Locos EMD/ALCO

SUSPENSION SYSTEMS

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TV Type Shocker - Conventional Coaches
NTa Type Shockers EMU Coaches with Air Suspension
Ta Type Dampers - Conventional Locos
Dampers for LHB Coaches, ABB Locos, EMD Loco, Self Propelled Cars

COMPOSITE MATERIAL

CBB for Freight application L Type
CBB for Coaching application K Type
CBB for EMU application K Type
CBB for Loco application L Type
Disc Pads for LHB / Metro Coaches

VESTIBULES

Fire Retardant Vestibules for Passenger Coaches - Conventional/LHB

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II.4 KNOWLEDGE MANAGEMENT CENTRE
Set up in 1976, the Escorts Knowledge Management Centre (KMC) is spread over 100,000 sq.m.
area in Faridabad. This centre designs the entire tractor engine, transmission plus hydraulic
systems and vehicle design consisting of sheet metal (including styling), controls and
accessories.
The KMC has facilities such as engine laboratory featuring computerized test beds with online
control, data acquisition and analysis, advanced vehicle testing laboratory, noise vibration and
harshness lab, metrology lab, and materials engineering lab. The KMC uses 3D-modeling,
analysis and simulation software for engines, transmissions and vehicles. Physical prototypes are
then tested for performance, durability and reliability.
II.4.1OBJECTIVES
The main objectives of my research on management of working capital of escort private
limited are:-

1) To study & evaluate the working capital management system of ESCORTS private
limited.

2) To determine the adequate or optimum quantum of investment in working capitalof
ESCORTS private limited.

3) To determine the composition or structure of current assets.

4) To maintain a proper balance between liquidity & profitability.

5) To maintain a proper the policy or means of finance for current assets.

II.4.2 INTRODUCTION TO WORKING CAPITAL

Cash is the lifeline of a company. If this lifeline deteriorates, so does the company's ability to
fund operations, reinvest and meet capital requirements and payments. Understanding a
company's cash flow health is essential to making investment decisions. A good way to judge a
company's cash flow prospects is to look at its working capital management (WCM).

II.4.3 WHAT IS WORKING CAPITAL

Working capital refers to the cash a business requires for day-to-day operations, or, more
specifically, for financing the conversion of raw materials into finished goods, which the
company sells for payment. Among the most important items of working capital are levels of
inventory, accounts receivable, and accounts payable. Analysts look at these items for signs of a
company's efficiency and financial strength.

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II.4.4 CONCEPTS OF WORKING CAPITAL
There are two concepts of working capital gross and net.

GROSS WORKING CAPITAL: It refers to the firms Investment in current assets
which can be converted into cash within an accounting year(or operating cycle) and
include cash, short-term securities, debtors, (accounts receivable or book debts) bills
receivable and stock (inventory)

NET WORKING CAPITAL: It refers to the difference between Current Assets &
Current Liabilities. Current liabilities are those claims of outsiders which are expected
to mature for payment within an Accounting year and include creditors (accounts
payable) ,bills payable and outstanding expenses. Net working capital can be positive
or negative. A positive net working capital will arise when Current Assets increase
current liabilities. A negative net working capital will occur when Current Liabilities
are in excess of Current Assets.

II.4.5. NATURE OF WORKING CAPITAL

EXCESSIVE AND INADEQUATE WORKING CAPITAL:
A business enterprise should maintain adequate working capital according to the needs of its
business of its business operations. The amount of working capital should neither be excessive
nor adequate. If the working capital is excess of its requirements it means idle funds adding to
the cost of capital is short of its requirements, it will result in production interruptions and
reduction of sales and, in turn, will affect the profitability of the business adversely.

DEFECIENCIES OF EXCESSIVE WORKING CAPITAL

EXCESSIVE INVENTORY: Excessive working capital results in unnecessary
accumulation of large inventory. It increases the chances of misuse, waste, theft etc.
EXCESSIVE DEBTORS: Excessive working capital will result in liberal credit policy
which, in turn, will result in higher amount tied up in debtors and higher incidence of bad
debts.
ADVERSE EFFECT ON PROFITABILITY: Excessive working capital means idle funds
in the business which adds to the cost of capital but earns no profits for the firm. Hence it
has a bad effect on profitability of the firm.
INEFFECIENCY OF MANAGEMENT: Management becomes careless due to excessive
resources at their command. It results in laxity of control on epenses and cash resources.

DEFECIENCIES OF INADEQUATE WORKING CAPITAL:

DIFFICULTY IN AVALIABILITY OF RAW-MATERIAL: Inadequacy of working
capital results in non-payment of creditors on time. As a result the credit purchase of
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goods on favorable terms becomes increasingly difficult. Also, the firm cannot avail the
cash.
FULL UTILISATION OF FIXED ASSETS NOT POSSIBLE: Due to the frequent
interruption in supply of raw materials and paucity of stock, the firm cant make full
utilization of its machines etc.
DIFFICULTY IN THE MAINTAINENCE OF MACHINERY: Due to the shortage of
working capital, machines are not cared and maintained properly which results in the
closure of production of on many occasions.
DECRAESE IN CREDIT RATING: Because of inadequacy of working capital, firm is
unable to pay its short term obligations on time. It decays the firms relation with its
bankers and it becomes difficult for the firm to borrow in case of need.

ADVANTAGES OF ADEQUATE WORKING CAPITAL:

AVAILIABILTY OF RAW MATERIAL REGULARLY: Adequacy of working capital makes it
possible for a firm to pay the suppliers of raw material in time. As a result it will
continue to receive regular supplies of raw materials and thus there will be no
disruption in production process.
FULL UTILISATION OF FIXED ASSETS: Adequacy of working capital makes it possible for
a firm to utilize its fixed assets fully and continuously. For eg. , if there is inadequate
stock of raw material, the machines will not be utilized in full and their productivity
will be reduced.
CASH DICOUNT: A firm having the adequate working capital can avail the cash discount by
purchasing the goods for cash or by making the payment before the due date.
MEETING UNSEEN CONTINGENCIES: Adequacy of working capital enables a company to
meet the unseen contingencies successfully.

II.4.6. NEED OF WORKING CAPITAL
Alongwith the fixed capital almost every business requires working capital though the extent of
working capital requirements differ in different businesses. Working capital is needed for
running the day-to-day business activities. When a business is started, working capital is needed
for purchasing raw material. The raw material is then converted into finished goods by incurring
some additional costs on it. Now goods sre sold. Sales do not convert into cash instantly because
there is invariably some credit sales. Thus, there exists a time lag between sales of goods and
receipt of cash. During this period, expenses are to be incurred for continuing the business
operations. For this purpose working capital is needed. Therefore, sufficient working capital is
needed which shall be involved from the purchase of raw material to the realization of cash. The
time period which is required to convert raw material into finished goods and then into cash is
known as operating cycle or cash cycle. The need for working capital can also be explained with
the help of operating cycle. Operating cycle of a manufacturing concern involves five phases:

(i) Conversion of cash into raw material.
(ii) Conversion of raw material into work-in-progress.
(iii) Conversion of work-in-progress into finished goods.
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(iv) Conversion of finished goods into debtors by credit sales.
(v) Conversion of debtors into cash by realizing cash from them.
Thus,the operating cycle starts from cash and then again restarts from cash. Need for working
capital depends upon period of operating cycle. Greater the period, more will be the need of
working capital. Period of operating cycle in a manufacturing concern is greater than a period of
operating cycle in a trading concern because in trading units cash is directly converted into
finished goods.

OPERATING CYCLE (NATURE OF WORKING CAPITAL)

Because of the time involved in a operating cycle, there is a need of working capital in the form
of current assets. Firms have to keep adequate stock of raw-material to avoid risk of non-
avaliabilty of raw materials. Similarly, concerns must have adequate stock of finished goods to
meet the demand in market on continuous basis and to avoid competition which necessitates the
money tied up in debtors and bills receivables. In addition to al these, concerns have to
necessarily keep cash to pay the manufacturing expenses etc. and to meet the contingencies.
CASH
RAW MATERIAL
WORK-IN-
PROGRESS
FINISHED GOODS
DEBTORS & BILLS
RECEIVABLES
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II.4.7 PERMANENT AND TEMPORARY WORKING CAPITAL:

Working capital in a business is needed because of operating cycle. But the need for working
capital does not come to an end after the cycle is completed. Since the operating cycle is
continuous process, there remains a need for continuous supply of working capital. However, the
amount of working capital required is not constant throughout the year, but keeps fluctuating. On
the basis of this concept, working capital is classified into two types:

(a) Permanent working capital: the need for working capital or current assets fluctuates
from time to time. However, to carry on day-to-day operations of the business
without any obstacles, a certain minimum level of raw materials, work-in-progress,
finished goods and cash must be maintained on a continuous basis. The amount
needed to maintain current assets on this minimum level is called permanent working
capital or regular working capital. The amount involved as permanent working capital
has to be met from long term sources of finance, eg. Capital, debentures, long term
loans etc.

(b) Temporary working capital: any amount over and above the permanent level of
working capital is called is called temporary, fluctuating or variable working capital.
Due to seasonal changes level of business activity is higher than normal during some
months of the year and therefore, additional working capital will be required along
with the permanent working capital it is so because during peak season demand rises
and more stock is to be maintained to meet the demand. Similarly, the amount of
debtors increases due to excessive sales. Additional working capital thus needed is
known as temporary working capital because once the season is over; the additional
demand will be no more. Need for temporary working capital should be met from
short term of finance, e.g. Short term loans etc. so that it can be refunded when it is
not required.

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III: MODULAR DESCRIPTION OF THE JOB ASSIGNED

ASSIGNED JOB 1: III.1. SHEET METAL COMPONENTS

Stamping facility is equipped with Ultra-modern presses from internationally renowned
suppliers. This facility delivers all type of sheet metal components i.e. Skin Panels, Inner Panels,
Floor Panels, Pillars, Reinforcements, Cross Members, Oil Pans, Fuel tanks etc. for Automotive,
Farm and Construction equipment, White Goods & other Industrial segments.
The sheet metal components processing includes three main processes which are required to
fulfill the given job. They are:

III.1.1. LAZER CUTTING
III.1.2. WELDING AND FAABRICATION
III.1.3. TESTING FACILITIES
We will be discussing each in details:

III.1.1. LAZER CUTTING
MACHINE USED: 2 Nos. Rapido 5 Axis Laser Cutting machine

RAPIDO Evoluzione has longer strokes (4080 x 1520 x 765 mm) and therefore the sizes and
type of components that can be processed have increased. Thanks to the extensively tried-and-
tested tool replacement system, each specific application is tackled in the best possible way.

The Safe Impact Protection System (SIPS) with full detachment of the head in the event of
accidental impact, prevents damage to the machine, parts and equipment and ensures immediate
restarting of production.
Laser cutting is a technology that uses a laser to cut materials, and is typically used for
industrial manufacturing applications, but is also starting to be used by schools, small businesses
and hobbyists. Laser cutting works by directing the output of a high-power laser, by computer, at
the material to be cut. The material then melts, burns, vaporizes away, or is blown away by a jet
of gas. leaving an edge with a high-quality surface finish. Industrial laser cutters are used to cut
flat-sheet material as well as structural and piping materials.
III.1.1.1. PROCESS
Generation of the laser beam involves stimulating a lasing material by electrical discharges or
lamps within a closed container. As the lasing material is stimulated, the beam is reflected
internally by means of a partial mirror, until it achieves sufficient energy to escape as a stream of
monochromatic coherent light. Mirrors or fiber optics are typically used to direct the coherent
light to a lens, which focuses the light at the work zone. The narrowest part of the focused beam
is generally less than 0.0125 inches (0.32 mm) in diameter. Depending upon material
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thickness, kerf widths as small as 0.004 inches (0.10 mm) are possible. In order to be able to start
cutting from somewhere else than the edge, a pierce is done before every cut.
There are many different methods in cutting using lasers, with different types used to cut
different material. Some of the methods are vaporization, melt and blow, melt blow and burn,
thermal stress cracking, scribing, cold cutting and burning stabilized laser cutting.

III.1.1.1.VAPORIZATION CUTTING
In vaporization cutting the focused beam heats the surface of the material to boiling point and
generates a keyhole. The keyhole leads to a sudden increase in absorptivity quickly deepening
the hole. As the hole deepens and the material boils, vapor generated erodes the molten walls
blowing ejecta out and further enlarging the hole. Non melting material such as wood, carbon
and thermoset plastics are usually cut by this method.

III.1.1.2. MELT AND BLOW
Melt and blow or fusion cutting uses high-pressure gas to blow molten material from the cutting
area, greatly decreasing the power requirement. First the material is heated to melting point then
a gas jet blows the molten material out of the kerf avoiding the need to raise the temperature of
the material any further. Materials cut with this process are usually metals.

III.1.1.3. THERMAL STRESS CRACKING
Brittle materials are particularly sensitive to thermal fracture, a feature exploited in thermal stress
cracking. A beam is focused on the surface causing localized heating and thermal expansion.
This results in a crack that can then be guided by moving the beam. The crack can be moved in
order of m/s. It is usually used in cutting of glass.

III.1.1.4. STEALTH DICING OF SILICON WAFERS
The separation of microelectronic chips as prepared in semiconductor device
fabrication from silicon wafers may be performed by the so-called stealth dicing process, which
operates with a pulsed Nd:YAG laser, the wavelength of which (1064 nm) is well adopted to the
electronic band gap of silicon (1.11 eV or 1117 nm).

III.1.1.5. REACTIVE CUTTING
Also called "burning stabilized laser gas cutting", "flame cutting". Reactive cutting is like
oxygen torch cutting but with a laser beam as the ignition source. Mostly used for cutting carbon
steel in thicknesses over 1 mm. This process can be used to cut very thick steel plates with
relatively little laser power.

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III.1.2. WELDING AND FAABRICATION
Under this section the welding or fabrication of the sheet metal components is generally done
with following methods:
III.1.2.1. SPOT WELDING
III.1.2.2. PROJECTION WELDING
III.1.2.3. SEAM WELDING
III.1.2.4. MIG BRAZING
III.1.2.5. ARC WELDING
We will discuss each further.

III.1.2.1. SPOT WELDING
Spot welding (RSW) is a process in which contacting metal surfaces are joined by the heat
obtained from resistance to electric current flow. Work-pieces are held together under pressure
exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in) thickness
range. The process uses two shaped copper alloy electrodes to concentrate welding current into a
small "spot" and to simultaneously clamp the sheets together. Forcing a large current through the
spot will melt the metal and form the weld. The attractive feature of spot welding is a lot of
energy can be delivered to the spot in a very short time (approximately ten milliseconds). That
permits the welding to occur without excessive heating to the rest of the sheet.

The amount of heat (energy) delivered to the spot is determined by the resistance between the
electrodes and the amperage and duration of the current. The amount of energy is chosen to
match the sheet's material properties, its thickness, and type of electrodes. Applying too little
energy won't melt the metal or will make a poor weld. Applying too much energy will melt too
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much metal, eject molten material, and make a hole rather than a weld. Another attractive feature
of spot welding is the energy delivered to the spot can be controlled to produce reliable welds.
III.1.2.2. PROJECTION WELDING
Projection welding is a modification of spot welding. In this process the weld is localized by
means of raised sections, or projections, on one or both of the workpieces to be joined. Heat is
concentrated at the projections, which permits the welding of heavier sections or the closer
spacing of welds. The projections can also serve as a means of positioning the workpieces.
Projection welding is often used to weld studs, nuts, and other screw machine parts to metal
plate. It's also frequently used to join crossed wires and bars. This is another high-production
process, and multiple projection welds can be arranged by suitable designing and jigging.

If the cross section of metal in the projection is fractured, the heat build up will form more
rapidly in the stretched material then at the workpiece interface area. This will result in the
projection collapsing before fusion takes place. When the projection is totally collapsed, further
growth of a weld nugget will be impossible since the large surface of the copper electrodes will
diffuse current density when the electrodes make full contact to the workpiece.
When the projection is collapsing, it is imperative that the electrode force be maintained
otherwise massive expulsion will occur. This expulsion is none other than the projection material
that needs to be fused to the workpiece. The cylinder is responsible for follow through.
Projection welding is very easy to maintain if the fundamentals are taken into consideration in
the first place. Steel wire shopping carts, wire racks, and other crosswire products are all
projection welding. Nuts and bolts are often assemble to other metal parts by projection welding.
If you want to produce a part with very little heat surface marks on one side of the panel, then
processing a projection on the alternate part and using large electrodes contoured to the finished
part would facilitate the goal.
III.1.2.3. SEAM WELDING
Resistance seam welding is a process that produces a weld at the faying surfaces of two similar
metals. The seam may be a butt joint or an overlap joint and is usually an automated process. It
differs from butt welding in that butt welding typically welds the entire joint at once and seam
welding forms the weld progressively, starting at one end. Like spot welding, seam welding
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relies on two electrodes, usually made from copper, to apply pressure and current. The electrodes
are disc shaped and rotate as the material passes between them. This allows the electrodes to stay
in constant contact with the material to make long continuous welds. The electrodes may also
move or assist the movement of the material.

A transformer supplies energy to the weld joint in the form of low voltage, high current AC
power. The joint of the work piece has high electrical resistance relative to the rest of the circuit
and is heated to its melting point by the current. The semi-molten surfaces are pressed together
by the welding pressure that creates a fusion bond, resulting in a uniformly welded structure.
Most seam welders use water cooling through the electrode, transformer and controller
assemblies due to the heat generated. Seam welding produces an extremely durable weld because
the joint is forged due to the heat and pressure applied. A properly welded joint formed by
resistance welding is typically stronger than the material from which it is formed.
A common use of seam welding is during the manufacture of round or rectangular steel tubing.
Seam welding has been used to manufacture steel beverage cans but is no longer used for this as
modern beverage cans are seamless aluminum.

III.1.2.4. MIG BRAZING
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG)
welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms
between a consumable wire electrode and the workpiece metal(s), which heats the workpiece
metal(s), causing them to melt, and join. Along with the wire electrode, a shielding gas feeds
through the welding gun, which shields the process from contaminants in the air. The process
can be semi-automatic or automatic. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating current, can be
used. There are four primary methods of metal transfer in GMAW, called globular, short-
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circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding
advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s,
GMAW was soon applied to steels because it provided faster welding time compared to other
welding processes. The cost of inert gas limited its use in steels until several years later, when
the use of semi-inert gases such as carbon dioxide became common. Further developments
during the 1950s and 1960s gave the process more versatility and as a result, it became a highly
used industrial process. Today, GMAW is the most common industrial welding process,
preferred for its versatility, speed and the relative ease of adapting the process to robotic
automation. Unlike welding processes that do not employ a shielding gas, such as shielded metal
arc welding, it is rarely used outdoors or in other areas of air volatility. A related process, flux
cored arc welding, often does not use a shielding gas, but instead employs an electrode wire that
is hollow and filled with flux.

III.1.2.5. ARC WELDING
Arc welding is a type of welding that uses a welding power supply to create an electric
arc between an electrode and the base material to melt the metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes. The welding region is usually protected by some type of shielding gas,
vapor, and/or slag.
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III.1.3. TESTING FACILITIES
The following testing methods are used:
Mechanical and Chemical composition tester
Cupping Tester
Universal Tensile Tester
Destructive / Non Destructive Testing for welding joints
3 D Co-ordinate Measuring Machine

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ASSIGNED JOB 2: III.2. HYDRAULIC COMPONENTS

The term hydraulic refers to fluids under pressure. Any liquid can be placed under pressure,
but not all liquids are used for hydraulic work. An undrained garden hose left lying in the sun
serves as an example. When we turn the nozzle on, solar-heated water erupts from the hose with
great force. Water, however, becomes steam at 212 degrees Fahrenheit and could not be used as
a working hydraulic fluid. Oil is the common hydraulic fluid used with farm equipment.

III.2.1.PRECAUTIONS WHEN USING HYDRAULICS

To safely and correctly operate hydraulic systems, understand these three points:
III.2.1.1. CLEAN OIL NEEDS
III.2.1.2. HEAT GENERATED BY USE
III.2.1.3. OIL LEAKS UNDER PRESSURE

III.2.1.1. CLEAN OIL NEEDS

Hydraulic pumps and control Valves operate with minute clearances (tolerances). Grit, grime,
and dirt pushed through these openings can eventually wear the surfaces and damage the system.
Clean hydraulic oil must be used. The fill area and connections must be kept clean as well. Dirt
is the greatest source of hydraulic system damage.

III.2.1.2. HEAT GENERATED BY USE

As hydraulic fluid moves through the closed system, the fluid meets resistance from the load to
be lifted or moved. Pressure increases and heat from friction builds. Under extreme load
conditions, the reinforced hoses can become hot, however, metal connections, fittings, and
piping can become super-heated. Place your hand near the connection to sense for heat before
touching the connection. If hot, allow the hydraulic system to cool down before touching the
heated connections.

III.2.1.3. OIL LEAKS UNDER PRESSURE
Pressure within the hydraulic system can exceed 2000 pounds per square inch (psi). Reinforced
hoses develop pin hole leaks and hydraulic connections can vibrate loose. Hydraulic leaks may
be hard to see. Never check for these leaks with your hand. The high pressure can inject oil
droplets under your skin. Oil injected under your skin is a medical emergency and will require
immediate medical care. Gangrene can occur, and limb amputation may be necessary. Use a
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mirror or piece of cardboard to check for high pressure hydraulic leaks. Do not use your skin.Pin
hole leaks are often invisible.

III.2.2.FITTINGS AND CONNECTIONS
III.2.2.1. Connecting Hydraulic Hoses to Couplers
Hydraulic couplers make the connections quick and simple to use. Follow these steps.
1. Use gloves or a wipe cloth to remove dirt and grit from the couplers.
2. Remove the dust covers from the couplers.
3. Push the couplers together until the lock ring snaps the two parts securely. Older style lock
levers and manual pull lockrings may be found also.

If you cannot easily make the connection, try the following:
a. While seated on the tractor where no hydraulic lift arms or other moving parts can crush you,
move the hydraulic control levers back and forth to release the static pressure. The previous
operator may have failed to do this.
b. Move the locking ring of the female coupler back and forth to be sure that dirt has not blocked
its movement.

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III.2.2.1. Disconnecting Hydraulic Hoses
To disconnect hydraulic hoses:
relieve the static pressure
push back on the lock ring
remove the hydraulic hose
replace the dust caps on each connector
hang the hoses on the implement
keep hoses off the ground
III.2.3.SAFETY ACTIVITIES
1. On several different tractors, identify all the hydraulic system components that are external to
the tractor. You may wish to name the parts and their purpose to a friend or mentor.
2. To supplement your knowledge of the hydraulic systems components, examine a log splitter
and identify all the hydraulic components. You may wish to demonstrate the location, the name,
and the function of each part to a friend or mentor.
3. Check the hydraulic fluid level of several tractors.
4. Practice connecting the hydraulic hoses to the tractor coupler.
5. Use the tractor hydraulic system for practice:
a. raising and lowering the 3-point hitch arms
b. raising and lowering a high-lift bucket
c. tilting a high-lift bucket.

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IV. DETAILED ANALYSIS OF INDIVIDUAL MODULE
ASSIGNED DEPARTMENT: AGRI MACHINERY

At Escorts Agri Machinery, the catalyst for the next wave of farm mechanization has brought
about two large customer centric initiatives to the fore at Escorts New Products and variants
that are aligned with changing and emerging applications & end usages and the shift of Escorts
from being a standalone tractor manufacturer to being a complete 'Farm Solution' provider.

The Escorts Jai Kisan Series recognizes the new market order for varied needs of the Indian
farmer, changing tractor uses for specialized applications and usage of modern and heavy-duty
implements & attachments, thereby offering wider options for agricultural, infrastructure as well
as specialized applications for land development activities.

The Jai Kisan Series comes in five new categories ValueMaxx, LoadMaxx, AgMaxx,
InfraMaxx and SuperMaxx. While the VALUEMAXX is the variant for basic agricultural
purposes, the LOADMAXX and AGMAXX variants specialize in haulage-based applications
and specialized Agri-applications respectively. The SUPERMAXX series is ideal for all types of
agriculture and non-farming purposes besides offering add-on applications for dual needs where
as, the INFRAMXX variant would specialize in infrastructure-based applications. The 'Jai Kisan
Series is currently available in the FARMTRAC line of Escorts tractors.

Let me explain a few of there famous tractors which I have handled.

IV.1 TRACTOR CONFIGURATIONS
Tractors can be generally classified as two-wheel drive, two-wheel drive with front wheel
assist, four-wheel drive (often with articulated steering), or track tractors (with either two or four
powered rubber tracks).
The classic farm tractor is a simple open vehicle, with two very large driving wheels on an axle
below and slightly behind a single seat (the seat and steering wheel consequently are in the
center), and the engine in front of the driver, with two steerable wheels below the engine
compartment. This basic design has remained unchanged for a number of years, but enclosed
cabs are fitted on almost all modern models, for reasons of operator safety and comfort. In some
localities with heavy or wet soils, notably in the central valley of california,
the "caterpillar" or "crawler" type of tracked tractor became popular in the 1930s, due to superior
traction and flotation. These were usually maneuvered through the use of turning brake pedals
and separate track clutches operated by levers rather than a steering wheel.
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Four-wheel drive tractors began to appear in the 1960s. Some four-wheel drive tractors have the
standard "two large, two small" configuration typical of smaller tractors, while some have four
large, powered wheels. The larger tractors are typically an articulated, center-hinged design
steered by hydraulic cylinders that move the forward power unit while the trailing unit is not
steered separately.
IV.2 ENGINE AND FUELS
The predecessors of modern tractors, traction engines, used steam engines for power. Since the
turn of the 20th century, internal combustion engines have been the power source of choice.
Between 1900 and 1960, gasoline was the predominant fuel, withkerosene (the Rumely Oil
Pull was the most notable of this kind) and ethanol being common alternatives. Generally, one
engine could burn any of those, although cold starting was easiest on gasoline. Often, a small
auxiliary fuel tank was available to hold gasoline for cold starting and warm-up, while the main
fuel tank held whatever fuel was most convenient or least expensive for the particular
farmer. Dieselisation gained momentum starting in the 1960s, and modern farm tractors usually
employ diesel engines, which range in power output from 18 to 575 horsepower (15 to
480 kW). Size and output are dependent on application, with smaller tractors used for lawn
mowing, landscaping, orchard work, and truck farming, and larger tractors for vast fields of
wheat, maize, soy, and other bulk crops. Liquified petroleum gas (LPG) or propanealso have
been used as tractor fuels, but require special pressurized fuel tanks and filling equipment, so are
less prevalent in most markets. In some countries such as Germany, biodiesel is often
used. Some other biofuels such as straight vegetable oil are also being used by some farmers.

IV.3 FARMTRAC
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Exported to the most advanced markets in the world.
Well accepted internationally for its versatility.
Designed for the demanding requirements of progressive farmers.
Machine with powerful features for maximum efficiency.

IV.4 POWERTRAC

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India's No.1 Economy Range - "Diesel Savers"

Engineered to give spectacular diesel economy.

The Diesel Saver technology - Great savings.

Powertrac DS plus series

IV.5:COMPONENTS USED IN ASSIGNED JOB
IV.5.1: SHEET METAL
The sheet metal components are divided into three parts:
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IV.5.1.1. SKIN PANEL COMPONENTS
IV.5.1.2. INNER COMPONENTS
IV.5.1.3. PILLARS, REINFORCEMENTS & STIFFENERS
IV.5.1.1. SKIN PANEL COMPONENTS

IV.5.1.2. INNER COMPONENTS

IV.5.1.3. PILLARS, REINFORCEMENTS & STIFFENERS

IV.5.2: HYDRAULIC COMPONENTS
The different types of valves used as hydraulic components are given below:
CONTROL VALVE:

FEATHERING VALVE:

RELEASE VALVE:
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COMPOSITE VALVE:

RELIEF VALVE:

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V.1 PROJECT UNDERTAKEN 1:

METHODS INVOLVED IN THE PROCESS OF
PRODUCTION OF REAR AXLE

DESIGN OF THE REAR AXLE SHAFT

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V.1.1 REAR AXLE PRODUCTION UNIT
S. No Operation
description
Machine
equipment
Operation Cycle
time(minutes)
1 Finish turning of
big end flange
Ncl-15; ncl-16
Kws make cnc
lathe
1. Drum dia
2. Big end flange dia
3. Length of drum
dia
4. Flange width
8.99(57 jps)
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5. Length of seal dia
6. Length of bearing
dia
7. Thread size
8. Thread length
9. Length of splines
10. Length of seal dia
11. Stem dia
12. Fillet radius of
stem taper dia
13. Surface finishing
of stem taper dia
2. Drill and finish
hole mill 8 nos
bolt holes
through and drill
2 nos
manufacturing
holes
Hmd-19
Batlibol make
multidrilling
machine
1. Bolt hole dia
2. Bolt hole co-
ordinates
3. Manufacturing
hole dia
4. Manufacturing
hole co-ordinates
4.25(124 jps)
3. Form oil groove
on stem end face
Etl-01 1. Oil groove depth
2. Oil groove profile
3.43(140 jps)
4. Chamfering of
back face of 8
nos bolt holes
Vlm-03 1. Chamfer dia
2. Chamfer angle
3.43(140 jps)
5. Milling of 38
involute splines
on stem end
Smm-02
Hurth make
spline milling
machine
1. No of splines dia
over measuring
pins.
2. Pcd runout
3. Length of splines
3.55(104 jps)
6. Washing of
component
Wsm-01
Thermas make
washing
machine
1. Effective case
depth on stem
2. Effective case
depth towards
flange dia
3. Effective case
depth at rest dia of
splines
4. Effective case
depth at root of
m-642 threads
5. Heat runout on
splined end
5(80 jps)
7. Induction
hardening of
shaft stem
Ihm-03
Ihm-04
1. Quenching media
2. Temp of
quenching media
3. Pressure of

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quenching media
4. Radial gap b/w
inductor &
component
5. Face gap b/w
inductor and
component
6. Quech lag time
7. Pre heating time
8. Power required
9. Spindle speed
10. Inductor
transverse rate
8. Check file
hardness at neck
& stem

9. Normalise the
shaft if required
for rework
Ihm-04
Induction
hardening
machine

10. Flange hardened
stem and face
Flange
hardening
equipment

11. Temper the
induction
hardened shaft
Tff-04
Tff-05
Tempering
furnace
Surface hardness Temp of
tempering
Tempering period
12. Straightening of
shaft stem
Hdp-05
Bemco make
hydraulic press
Runout on 47 involute
spline dia

13. Grinding of seal
dia & finish
Grinding of
bearing dia &
bearing seating
face
Agr-07
Angular head
grinder
1. Seal dia
2. Bearing dia
3. Surface finish on
bearing dia
4. Dist of bearing
seatingface from
flange front
3.45(139jps)
14. Finish grinding
of seal dia
Angular head
grinder
Agr-05
Length of seal dia
Surface finish of seal dia
2.91(165 jps)
15. Finish grind
stem and face
Mtc-01
Face grinding
equipments
1. Surface finish of
stem end face
2. Length of stem
end face wrt
bearing steating
face
4.21(132 jps)
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16. Super finish of
seal dia
Sfm-02
Suffina make
super finishing
machine
1. Seal dia
surface finish
of seal dia
2(132 jps)
16. Check crack on
rear axle shaft
Magna flux
crack detector
1. Free from
cracks

17. Final inspection
of shaft rear axle
Stage 2. As per part
print
specification
2(132 jps)
V.1.2. OPERATIONS PERFORMED
V.1.2.1. 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/mtr
04 0.012/RN 700ft/mtr

GAUGE USED

1. G-30327
2. G-85004/2
3. G-30405
4. G-85004/1
5. G-30329
6. G-30327
7. G-30345
8. G-30343

V.1.2.2.TESTING SHAFT RUNOUT CHECKING AFTER CNC

OPERATERS 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 the machine.

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V.1.2.3.TO DRILL AND REAM 8 BOLT HOLES ON FLANGE

DRILL TWO MANUFACTURING HOLES.

Operation Gauges Checking frequency
Position of 8 holes after drilling 4235 aaeg 27 1 shift
Position of 8 holes after milling 4235 aaeg 4 1 shift
Dia 740/.760 G-40088 1/50
Dia .6675/.6595(hole mill) G-40087 1/10

DRILLS USED - 4235AA-ET-85A

HOLE MILLS - 4235AA ET 86A
4235AA EG 27
7235 AA EG 4

LIMIT GAUGES - G-40088
G-40087

V.1.2.4.OIL GROOVE ON STEM END FACE

CUTTER USED - FM CUTTER 4235 AET 5
CUTTING SPEED - 800 RPM
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FEED -BY HAND
GAUGE TO CHECK -4235 AEG 6

CHAMFER ON 8 HOLES

CHAMFER SIZE - .070+ 0.10X45
CHECKING FREQUENCY - 1/160
TOOL USED - TS COUNTERSUNK CUTTER DIA 3/4X90

V.1.2.5. FINISH MILL 38 & 47 INVOLUTE SPLINES

TOOL & M/C SETTINGS -
CUTTER - 4235A ET 83(FOR 47 SPLINE)
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REEMER - 4235A-ET 9(FOR 38 SPLINES)
FACE CENTRE - 4235AA EF 44/1
TAIL STOCK CENTRE - MA-321/25

GAUGES USED -
4235 EG 71
4235 AEG 29
4235 AEG 28
4235 AEG 72

SPEED - 180 RPM
FEED - 400M/MIN

V.1.2.6/SHAFT INDUCTION HARDENING

QUENCH PRESSURE = 5-7.5 Kg/cu.cm
QUENCH TEMPERATURE = 25C-45C
GAP = 0.085/.110

V.1.2.7. TEMPER INDUCTION HARDENING OF SHAFT

FURNACE TEMPERATURE - 230C-240C
TIME PERIOD - 1.5-2.5 HRS

CHARACTERISTICS -
CHANGE OF BASE COLOUR TO GOLDEN COLOUR.

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V.1.2.8. GRIND SEAL DIAMETER

GRINDING WHEEL - 4235 AET 87
CENTRE - MT-5(2 NOS)
DRESSING DIAMOND - MA 902/37

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V.1.2.8. FINISH GRIND SEAL DIAMETER

TAPER CUT GRINDING WHEEL :- 100/68X40X31.75

SUPER FINISH SEAL DIA :- 2.105/2

STONE USED :- 60mmX60mmX18mm

OSCILATOR DRIVE PRESSURE :- 1.5 2.5 BAR.
V.1.2.9. STAGE INSPECTION

CHECK LIST:-
1. 8 NOS BOLT HOLE DIA OF 0.6675/0.6595
2. SEAL DIA OF 2.100/2.105
3. SEAL DIA OF 2.6265/2.6275
4. LENGTH OF 29.096/29.042
5. 38 SPLINE FOR ALLIGNMENT
6. 47 SPLINE FOR ALLIGNMENT
7. IF ABOVE COMPONENT IS TIGHT THEN IT IS SENT FOR
REWORK.

V.1.2.10. CRACK CHECKING(MAGNA FLUX)

CURRENT RATING: - 2200-2800 AMPS
If blue light shows then piece is rejected otherwise passed with ok sign.

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V.2. PROJECT UNDERTAKEN 2:

METHODS INVOLVED IN THE
MANUFACTURING SHAFT HYDRAULIC
LIFT ARM

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V.2.1. OPERATION PERFORMED

V.2.1.1.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".
This process is used for reducing length and smoothening the face.

Tooling element :- STD Self Centering Vice
TGR-F-3951 PADS
Swiveling Stopper

Cutting Tool Details :- STD Centre Drill DIA 5/16 inch
STD Face Mill Cutter

Speed :- Centre Drill -1000rpm
Face Mill Cutter -139rpm

Cutting Time :- 1.5 min

Tool Life :- Centre Drill 500 components
Face Mill Cutter 100 components
Gauge Details :- STD Height gauge (0-500)
TGR-G-9120 Centre Depth Checking Gauge 5.20/5.0

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V.2.1.2.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 scaleon 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 51.000.15
DIAL indicator L.C 0.01

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V.2.1.3.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 workpiece to
exact size when it is hot, it will be undersize when it has cooled.

Perhaps the most difficult operation in machine work is to make accurate measurements. So
much depends on the accuracy of the work that you should make every effort to become
proficient in the use of measuring instruments.

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
V.2.1.4.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
workpiece, which forms chips at the cutting edge.

Machine name :- Radial drill machine

Tooling element :- quick change chuck and sleeve

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Cutting tool :- HSS drill dia 11.5 mm
Counter drill dia 13 mm
Tap 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 20 UNF-2B thread
Center distance gauge
FTHL-G-9008

V.2.1.5.HOBBING

Hobbing uses a hobbing machine with two non-parallel spindles, one mounted with a blank
workpiece and the other with the hob. The angle between the hob's spindle and the workpiece'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. Note that the previous example only holds true
for a single threaded hob; if the hob has multiple threads then the speed ratio must be multiplied
by the number of threads on the hob. The hob is then fed up into workpiece until the correct
tooth depth is obtained. Finally the hob is fed into the workpiece parallel to the blank's axis of
rotation.
Up to five teeth can be cut into the workpiece at the same time. Oftentimes multiple gears are cut
at the same time.
For larger gears the blank is usually gashed to the rough shape to make hobbing easier.

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
CONCENTICIT BENCH

V.2.1.6.ROLLING

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Tooling Element :- STD Collet for clamping
ALT. for Hobbing

Cutting Tool Details :- STD Grob Rool
HOB Cutter

Cutting Time :- 2 min

Gauge Details :- Outside Micrometer 50-75mm
Least count - 0.01mm
FTHL-G-9030
Serration Ring Gauge Go

V.2.1.7.WELDING
The arc welding makes arcs between a material and a welding rod. And it is a well used welding
method. In the arc welding, we use a torch with a welding rod as shown in Figure 1. And both of
the material and the welding rod are meant in the arc. The arc welding is very high speed, and if
the welding is very well, the strength is very high. But the arc is very light, then we cannot see
the welding processes. All weldings, including the arc welding, need higher technique than
cutting processings, because we do not have the same conditions.

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V.2.1.8.GRINDING

Grinding practice is a large and diverse area of toolmaking. It can produce very fine finishes and
very accurate dimensions; yet in mass production contexts it can also rough out large volumes of
metal quite rapidly. It is usually better suited to the machining of very hard materials than is
"regular" machining (that is, cutting larger chips with cuttin tools such as tool bits or milling
cutters), and until recent decades it was the only practical way to machine such materials as
hardened steels. Compared to "regular" machining, it is usually better suited to taking very
shallow cuts, such as reducing a shaft's diameter by half a thousand of an inch (thou).(1 thou ==
25 um)
Technically, grinding is a subset of cutting, as grinding is a true metal cutting process. Each
grain of abrasive functions as a microscopic single-point cutting edge (although of high negative
rake angle), and shears a tiny chip that is analogous to what would conventionally be called a
"cut" chip (turning, milling, drilling, tapping, etc.). However, among people who work in the
machining fields, the term cutting is often understood to refer to the macroscopic cutting
operations, and grinding is often mentally categorized as a "separate" process. This is why the
terms are usually used in contradistinction in shop-floor practice, even though technically
grinding is a subset of cutting.

Tooling element :- Grinding abrasive wheel
Speed :- 39 and 220 rpm
Cutting tool :- Pneumatic grinder

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V.2.1.9.HARDENING & TEMPERING

Tempering is a heat treatment technique for metals, alloys and glass. tempering is done to
"toughen" the metal by transforming brittle martensite or bainite into a combination of ferrite and
cementite. Precipitation hardening alloys, like many grades of aluminum and superalloys, are
tempered to precipitate intermetallic particles which strengthen the metal. Tempering is
accomplished by a controlled reheating of the work piece to a temperature below its lower
critical temperature.
The brittle martensite becomes tough and ductile after it is tempered. Carbon atoms were trapped
in the austenite when it was rapidly cooled, typically by oil or water quenching, forming the
martensite. The martensite becomes strong after being tempered because when reheated, the
microstructure can rearrange and the carbon atoms can diffuse out of the distorted body-centred-
tetragonal (BCT) structure. After the carbon diffuses, the result is nearly pure ferrite with body-
centred structure.
In metallurgy, there is always a trade-off between strength and ductility. Precise control of time
and temperature during the tempering process are critical to achieve a metal with well balanced
mechanical properties.

Power :- 220-244 V

Pre-Heating Time :- 1.4 sec

Feed Rate :- 9mm/sec (53 spline gauge)

Quench dwell time :- 32 sec

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Speed :- 80 rpm

V.2.1.10.INSPECTION

Inspection is the last stage of manufacturing.it is done manually to check for defects and other
irregularities.

Gauge details :- SERRATION RING GAUGE
FTHL-G-9030 GO
SERRATION RING GAUGE
FTHL-G-9031 NO GO
ON MATERIAL 6 SPLINE

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V1. INDUSTURY APPLICATIONS

The Escorts Training & Development Centre (ETDC), was established way back in 1969 at
Bangalore to expand the potential of our intellectual capital. Spread over 85 acres of fertile land,
it is a scientifically planned training complex including training halls, model workshops, and
residential cottages and hostels covering 14 acres of land with facilities including canteens,
dining halls, indoor & outdoor recreational areas. Another 76 acres is dedicated to model and
demonstration.farming.

ETDC provides training to farmers, employees, dealers, salesmen, service in-charge, parts in-
charge, mechanics, financial institutions, government nominees, and agricultural & engineering
students. Escorts has till date achieved 3.25 lakh mandays in various training programmes at
ETDC.

ETDC is equipped with modern teaching aids including multimedia, computer learning centre,
training literature in several languages, technical films, slide shows, extensive library for archival
materials on various farming techniques, automobiles, agricultural engineering and management.
Its applications are further divided into two sections.
1. Agricultural applications
2. Non-agricultural applications

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V1.1 AGRICULTURE APPLICATION
VI.1.1 TILLAGE APPLICATION
ROTAVATOR

RECOMMENDED TRACTOR MODELS

Rotary Tiller Size Light & Medium soils Heavy & Black Cotton soils
4 Ft PT 434, FT Hero FT Champion & PT 439
5 Ft FT Champion, PT 439 FT 45, PT 445
6 Ft PT 445 , FT 45 FT 60 , PT4455, FT 65
7 Ft FT 60 , FT 65 , PT 4455 FT 65 , PT 4455
8 Ft FT-70 FT-70

PRODUCT FEATURES

Side Gear Drive: Sturdy & Low Maintenance

Heavy Duty Frame: Helps in balancing of the rotary tiller & helps in achieving higher depths

Specially designed BALANCED ROTOR: Reduces load on Tractor & avoids tyre slippage

Heavy Duty Propeller Shaft: Higher Torque Transmitting capacity.

High Quality Hardened Steel Blades: Low wear & tear & better pulverization

Multi Speed Heavy Duty Gear Box: This helps in using the same rotary tiller in various soil
conditions to achieve different pulverization levels depending upon the requirement.

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BENEFITS
Reduces the land preparation cost to half
Fine Tillage up to 4-9 inches in optimum soil condition.
Retains soil moisture and increases soil porosity and aeration, which enhance
germination and growth of crops.
Cuts and mixes crop residue with soil making it rich in organic matter
Saves time, fuel and money as it combines all three operations of Tillage, Pulverization
and Leveling in a single operation
Low Diesel consumption vis--vis traditional implements used for cultivation.

MB PLOUGH

HYDRAULICALLY REVERSIBLE MB PLOUGH PRODUCT PROFILE

Product
Range
2 Bottom Hydraucially Reversible MB
Plough
3 Bottom Hydraucially Reversible MB
Plough
Size 2x12" 2x14" 2x16"

3x12" 3x14" 3x16"

Tractor HP 40-45 45-50 50-55

55-60 60-65 60-65

PRODUCT FEATURES
Hydraulically operated
Plough Shovel tilt angle adjuster
High inter body clearance
Better range of Working depths
High quality product

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SPECIFICATIONS

Model 2 MB PLOUGH 3 MB PLOUGH
Size of Plough
No. of bottom
Working with of each bottom
Under frame point clearance
Inter body gap
Type of Mould board
Type of share
Horizontal suction
Vertical suction
HP required (min-Max)
Tractor engine speed (rpm)
Working Depth (min-max)
Working Depth Control
Working Width
Parking stand
Weight (Kg.)

2130 mm
Two
304 mm(12")
700 mm
850 mm
B 25 HB
SB 45
10 mm
10-20 mm
45-65 Hp
1600-2000 rpm
8"-13"
Up to-+30 mm
610 mm(24")
YES
430 kg

3020 mm
Three
304 mm(12")
700 mm
850 mm
B 25 HB
SB 45
10 mm
10-20 mm
65-75 Hp
1600-2000 rpm
8"-13"
Upto-+30 mm
915 mm(36")
YES
550 kg

BENEFITS

Easy to operate
Helps for correct positioning
Uniform cut of the depth
Does not produce side thrust
Low maintenance
Increases the yield
Long Life

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VI.1.2 LEVELING APPLICATION

PRODUCT FEATURES

More leveled and smooth soil surface.

More uniform moisture environment for crops.

Reduced consumption of seeds, fertilizers, chemicals and fuel.

Improved field trafficability (for subsequent operations).

LAZER LEVELER
SPECIFICATIONS
Drag Bucket

Length x Height x width
Thickness
Weight
Main frame and Drawbar
Length x Height x width
6.5 x 2 x 2.5 ft
10 mm
400 kg
127 x 6 mm and 75 x 40 mm
6.5 x 2 x 2.5 ft

Tyre

Size 16x6 (8 Ply)
Assembly box 65x6 mm with taper roller bearing

BENEFITS

Decreases the time to complete task of irrigation.

Reduces weed problems.

Improves uniformity of crop maturity.

Reduces the amount of water required for land preparation

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VI.1.3 HARVESTING APPLICATIONS
COMBINE HARVESTER

PRODUCT FEATURES

Easy to tractor mount option

Hydraulic steering

Rugged design, strong structure

High quality product

SPECIFICATIONS
Chassis 46" (1168 mm)
Straw walker 5 no. 5 steps
Cutter bar
Width 141" (3581 mm)
Height 2"-41"(55-1050 mm)
Tyres Rear tyres (7.50 x 16) 12 PR
Power > 55 hp
Overall dimensions
Length 312"(7925mm)
Width 156"(3962mm)
Height 156"(3962mm)
Weight 4800 kg.

BENEFITS
Dual usage of tractors
Easy to operate, less fatigue
Works in difficult field conditions
Less grain loss
Better Return on Investment

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VI.2 NON-AGRICULTURE APPLICATION
VI.2.1 MATERIAL HANDLING APPLICATION
BACKHOE LOADER

BACKHOE FEATURES

Heavy duty backhoe with 5700 kgf tear out force

Shortest cycle time in its category (12-14 seconds)

Excavation output- 1400-1800 cu.ft/hr with 0.21/0.23 cu.m buckets

Low diesel consumption

Spares & service avalibility at customer's door-step

LOADER FEATURES

Heavy duty loader
3-D positional valve mechanism for enhanced operator comfort
Bucket level indicator for superior loader application
BQRSL Mechanism enables exchanging of buckets within seconds by operating
single lever
Option of various dump loader heights: 2.7m, 3.0m, 4.0m dump heights

SPECIFICATIONS
LOADERS

Loader Hinge Pin Height
Load Over Height
Dump Height @45
With Optional Booster
Bucket (dump Height)
Reach At Full Height
FullyDumped
Working Depth
Dump Angle
STD V2 LOADER
mm (feet inches)
3350 (11")
3100 (10 2")
2680 (8 8)

700 (2 3")
150 (5")
90
60
EXT_HT_V2_LOADER
mm (feet inches)
3700 (12 13")
35200 (11 5")
2988 (9 8")
4195 (13 7")
700 (2 3")
150 (5")
90
60
MAXX_V2_LOADER
mm (feet inches)
3700 (12 13")
4350(14 3")
2988 (9 8")
4196 (13 7")
700 (2 3")
150 (5")
45
60
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Roll Back At Ground
Bucket Capacity
Output (90% bucket cap
& 40Sec opn cucle time)
0.6 cu.m. (900 kg)
48.6 cum/hr = 1700
cu.ft/hr
0.6 cu.m. (900kg)

0.6 cu.m. (900 kg)

BACKONE
Maximum digging depth
Maximum load over height
Maximum reach at ground level
Dozer width
King post travel
Boom rotation
Maximum tear out Bucket + Dipper
SPECIFICATION
3500 mm (11.5 ft)
3140 mm (10.3 ft)
440 mm (14.43 )
2400 mm (7.9 ft )
1150 mm (3.7 ft )
180 * degree
5700 kgf
DOZER

PRODUCT FEATURES
Direct control valve with relief valve
Strong cross section and highly quality steel
Twin cutting blade
Easy detachable
Additional pressure release valve(PRV)-protects hydraulic system during overloading

SPECIFICATIONS
DESCRIPTION
Blade Size
Ground Clearance
No. of Cylinders
Cutting Depth
Arm Structure
SPECIFICATION
2350mm x 750mm/2450mm x 800mm
775mm 900mm
two/one
120mm
standard Box Sections
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Chassis Structure
Blade Section
Hardware
Cylinder
Hoses
Cutting Edge
Raw material
Profiles
ISMC standard
Single MS bend Plate
On brako make high tensile
Dantal, Fasto make
Parker make
Hardened EN8 flat twin
Essar Steel IS2062B
Laser CNC cutting

BENEFITS
Prevent overloading of hydraulic system
Low maintaince
Longer life
Easy removal and fitting
Blade changing cost is less.

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CONCLUSION

I hereby conclude that after attending the six weeks industrial training in THE
ESCORTS GROUP, MATHURA ROAD, FARIDABAD in SHEET METAL AND
HYRAULLIC COMPONENTS. I had gained a knowledge of COMPONENT designing using
DIFFERENT METHODS of welding .on the design farmtrac And powertrac , I have become
familiar with various modules such as auto components , welding methods, fixing of
components, safety measurements etc.
I have also got knowledge about designing the given component and how to test it
with all the safety measurments. This helps me gaining a lot of knowledge about the
implementation of a particular design tractor.

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BIBLOGRAPHY

1. www.escorts.com
2. www.wikipedia.com
3. www.tracmanufacture.com
4. www.tracojack.com
5. www.project.com
6. www.scribd.com

TRAINING REPORT Escort Tractors

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