Training Report.docx

Summer Training Report on Tractor Assembly and Parts

Made by: Mechanical Engg.

Acknowledgement Sometimes words fall short to show gratitude, the same happened with me during this project. The immense help and support received from Mahindra & Mahindra Ltd. Limited overwhelmed me during the project. It was a great opportunity for me to work with Mahindra Tractor division, pioneers in the field of farm equipment manufacture, a part of Mahindra and Mahindra Ltd. I am extremely grateful to the entire team of Mahindra Tractors, Vill. -Mehlan, Jaipur who has shared their expertise and knowledge with me and without whom the completion of this project and my industrial training would have been virtually impossible. My sincere gratitude to Mr. Utkarsh Dubey (Senior Manager and my mentor, Mahindra division, Mahindra and Mahindra Ltd.) for providing me with an opportunity to work with them as a trainee who has provided me with the necessary information and his valuable suggestion and comments on bringing out this report in the best possible way. I feel great pleasure to thank Mr. Avtar Singh (In charge-PDI) and all other team members. I am also very thankful to my friends, partners during the training period and all the workmen at the Mahindra Division, Plant -1 and who helped me in the completion of my projects. I am thankful to that power that always inspires me to take right step in the journey of success my life.

CONTENT 1. 2. 3. 4.

The Indian Tractor Industry Introduction Tractor Specification Technology  Multi disk oil impressed brakes  Constant mesh transmission  Sliding mesh transmission  Dual clutch transmission  Digi sense 5. Various parts 6. Manufacturing facilities  Light machine shop  Heavy machine shop  Paint shop  Assembly  Heat treatment shop  Quality engineering  Pre-delivery inspection

The Indian Tractor Industry India is mainly an agricultural country. Agriculture accounts for approximately 25 percent of India’s GDP. Agriculture in India is the means of livelihood of almost two thirds of the workforce in the country and employs nearly 62 percent of the population. It accounts for 13 percent of India’s exports. About 42 percent of India’s geographical area is used for agricultural activities. It is therefore considered a vital sector of the Indian economy. The Indian tractor industry is the largest in the world, accounting for one third of global production. The other major tractor markets in the world are China and the USA. The global spotlight on tractor manufacture in terms of unit volume seems to be swinging away from the USA, UK and Western and Eastern Europe towards India and China, where growth in the number of producers and the total volume of production in recent years has been impressive. Until 1960, the demand for tractors was met entirely through imports. Indigenous manufacture of tractors began in 1961, but India continued to import tractors to bridge the total volume needs up to the late 1970s. The Indian Tractor Industry has come a long way since then. Volume growth in the past four decades show a compound annual growth rate of 10 percent, despite seasonal variations that cause natural fluctuations in the demand for tractors, subsequently impacting the industry volumes. The Indian tractor market is traditionally a medium-horsepower market consisting of mostly 31-40hp, which constitutes almost 51 percent to growth in this category. Growth of the Industry is closely related to growth in this category. In other-size categories, 41-50 hp category achieved the second highest growth of 34 percent and constitutes 24 percent of the total market share. The rest of the market share is

largely with the 21-30 hp category followed by the category of tractors having more than 50 hp. The Indian Tractor Industry has numerous challenges, some of them being: 1.Reducing the average age of tractor buyers from the age group of above 40 to younger people. 2.Development of new products using latest technology and advancements in the field of electronics and mechatronics and making the tractors more comfortable, stylish and yet keeping them in range of a farmer. 3.Reduction of emissions in accordance with the new international emission standards.

Introduction Mahindra Tractor Division, Mahindra and Mahindra Limited, is the farm equipment manufacturer division and the flagship company of the erstwhile Punjab Tractors Limited of which a major share was acquired by Mahindra and Mahindra Limited in the year 2007. The Company's principal activity is to manufacture, market and servicing of tractors ranging from 25-100 HP. Other products include self-propelled harvester combines, forklifts, tractor drawn agricultural implements, gears, spare parts, casting and accessories. The Company has manufactured and sold more than 600,000 tractors over the past 30 years (with 36000 tractors being manufactured and sold in the fiscal year 2008-2009 alone). The basic credibility of the company is the manufacture of reliable tractors requiring least maintenance and low cost of ownership. The Company is one of the major share-holder in the Indian Tractor Industry in a market with rivals like John Deere, Case New Holland, TAFE, etc. The company has in-house competence in producing engines and transmission systems and has been the best financially managed company in the Indian Tractor Industry. The reputed Mahindra brand of the company is sold through 475 exclusive dealers stocking only Mahindra products. The manufacturing plants and the Research and Development centre of the company are located in Mohali, Punjab. The company exports auto components to the markets of African/SAARC countries. The company has 3 farm equipment manufacturing facilities: 1.Mahindra Tractor Division (MTD), Vill. -Mehlan, Jaipur 2.Mahindra Foundry Division (MFD), Vill. -Mehlan, Jaipur 3.Mahindra Combine Division (MCD), Vill. -Mehlan, Jaipur

MAHINDRA 475 DI Specifications No of Cylinder

=

4

Capacity, CC

=

2730

Engine Rated RPM

=

1900

Transmission Type

=

Partial Constant Mesh Transmission (Optional-Sliding Mesh)

No of Gears

=

Brake Type

=

8 Forward + 2 Reverse Oil brakes (optional)

Main Clutch Type & Size = Dual (optional) Lift Capacity at Hitch, KG =

1500 kg

Steering Type

=

Power steering (optional)

Fuel Tank Capacity, LIT

=

48 lit

Wheel Base MM

=

1945

Horse Power

=

42

TECHNOLOGY 1. Multi – disk oil immersed brakes Optimum braking performance and longer brake life thus ensuring lower maintenance and higher performance.

The purpose of a multi plate disc brake is the same as the more conventional calliper. It has to retard, stop and hold the vehicle. The fundamental difference is that it is self-contained and cooled by oil. In principle it’s not too different to a motorcycle clutch but of course the details are very different. The braking faces are between a number of interleaved friction discs and counter plates alternately keyed to the housing or splined to a driveshaft. The plates are clamped together to produce a braking torque either by an annular piston which is coaxial with the driveshaft or by a ball and ramp mechanism. Many vehicles using this type of brake have hub reduction gearing so it is common for oil immersed brakes to be inboard of this gearing and as such they run at five- or six-time wheel speed.

Annular Piston Brakes Annular piston brakes have the benefit of simplicity of construction. As the piston only moves in an axial direction to load the brake plates there is no inbuilt servo effect and the brake factor is one. A low brake factor means that the brake torque between left and right brakes will be more equal (since differences are not amplified) and the brake system will be more controllable, for a similar actuation. On the downside, to get a given torque output a bigger piston will be required and this together with the long rubber seals (one metre or more) consumes a greater fluid volume. In order to minimise pedal travel, in none power brake applications, annular piston brakes run with low clearances and often have a method of controlling the amount of piston retraction. Generally, this type of brake is manufactured ‘in house’ with only the plates being bought from a specialist brake supplier. Ball Ramp Brakes Ball ramp brakes have a mechanism inside the axle however if they are hydraulically applied the actuation is usually accessible from outside which helps to reduce servicing costs. In order to make a ball ramp actuator nonservo the actuator must be decoupled from the friction plates. This is best done by using a needle roller bearing but Yamaha use a low friction plain

bearing on this ATV brake as an acceptable trade-off between performance

and simplicity.

Friction Material Type There are four basic types of friction material available each with their own pros and cons, sintered, paper, graphitic, carbon. Sintered bronze is made by sintering a blend of powders into a porous matrix on a steel carrier plate. It is a tough durable material well able to live with overheating. On the downside it has a low dynamic friction and a high static / dynamic friction ratio which can cause chatter noise. Paper frictions materials are so called because of the manufacturing process as much as the material itself. They contain a range of fibres and friction modifiers which are then saturated in resins. The resulting material is soft and easily damaged. Paper materials have a high dynamic friction level and a low static / dynamic friction ratio which gives them good torque capacity and low noise however their energy capacity tends to be low. Graphitic materials are moulded compositions of graphite and resin binders. The have good thermal capacities which make them durable however they have a moderate static / dynamic friction ratio which may make them noisy.

Carbon linings give stable friction, high load and low wear but are very expensive as such they are rarely used. Groove Pattern Grooves are either machined or moulded into the friction material to aid oil flow and thus cooling. Numerous patterns exist and each friction plate manufacturer has his favourite however the following points should be born in mind: -The oil must be part of the cooling process. If large amounts of oil are present then the oil can flow quickly through the plates however if supply is limited then the flow through the plates should be restricted. Oil trapped between plates increases the parasitic drag losses and causes oil heating during breaks off running. Spiral - This grooving pattern may be used where there is limited oil available due to the design of the brake. The spiral pattern gives controlled oil flow through the grooves but will give high viscous drag. Radial - or sunburst pattern is suitable for applications in which sufficient oil is available. It facilitates high oil flow and quickly disperses heat whilst minimizing viscous drag. Waffle - or multiple pass patterns are compromises between spiral and radial and offer some oil flow restriction without increasing drag too much.

1. Partial Constant Mesh Transmission Allows easy and smooth gear shifting operation thereby ensuring longer life for the gear box and less driver fatigue.

CONSTANT MESH GEARBOX: Now the constant mesh gearbox is very good improvement to one discussed above. this one also has a primary reduction, a lay shaft, output shaft. but the main point is that the gears on both the shafts remain in a constant mesh all the time. the gears on lay shaft remain fixed to it but those on

output shaft sit on bearings. all the respective gear ratios are constantly meshed and keep rotating. Here we don’t have to wait for gearbox shaft to stop rotating so as to shift because of the unique selector and shifting mechanism. these gearboxes use dog clutch and cone clutch. the cone clutch lowers the rpm of the respective gear and the dog clutch is shifted to mesh with the dog teeth on the gears to lock up.

1. DOG CLUTCH A dog clutch is a mechanism used to connect and disconnect two rotating shafts or machine parts. It functions by mating a set of regularly spaced teeth or protrusions on one half of the clutch mechanism to a set of identical

recesses on the other, rather than using the friction principle used in other clutches. This has the benefit of allowing both shafts to turn at the same speed without slipping and with minimal clutch wear. They cannot, however, be used to control torque as is the case with a friction clutch. Dog clutches are commonly used in manual or stick shift automobile gearboxes, marine propeller drives, and on the drives of heavy machinery. This type of clutch is typically made up of two round plates, one fixed to the drive shaft and one to the shaft being driven. One of the plates has a series of evenly spaced protrusions machined into its face, similar to the battlements on top of a castle wall. The other has an identically spaced series of like-sized recesses cut into its face. When the two plates are brought together, the protrusions mate or fit into the recesses, thereby effectively joining the shafts and transferring rotational motion from one to the other. This ensures a strong mechanical coupling between the two components with no slip characteristics.

2. IDLER GEAR An idler gear is a gear wheel that is inserted between two or more other gear wheels. The purpose of an idler gear can be two-fold. Firstly, the idler gear will change the

direction of rotation of the output shaft.

3. LAY SHAFT A second or intermediate transmission shaft in a machine.

1.

SLIDING MESH GEARBOX:

In the sliding mesh the gears do not remain meshed with each other all the time but only those gears are meshed together whom we want to. all the gear isn’t rotating at the same time. the engine power is sent to the lay shaft that in the end has to be meshed with the gears on the output shaft. here the main point to be noticed is that the gears on the lay shaft are fixed to the shaft but the gears on the final drive shaft can slide across the shaft on splines horizontally. now the gears can be moved using the selector fork mechanism that pushes or pulls the gears using thrust bearings While shifting in a sliding mesh gearbox we notice that gears can’t be meshed while they are rotating at their respective RPM’s as it can destroy the gear teeth, for this it’s made sure that the lay shaft is not rotating or rotating slowly (double de-clutching), this is done by pressing the clutch for a while and then shifting the gear.

2. Dual Clutch Transmission

A dual-clutch transmission (DCT) (sometimes referred to as a twin-clutch transmission or double-clutch transmission) is a type of automatic transmission or automated automotive transmission. It uses two separate clutches for odd and even gear sets. 3. DIGI SENSE: Presenting

Digi sense - a smart technology solution, which enables

Mahindra tractor owners to be in complete control of their tractors 24x7 through the simple touch of a Smartphone. It empowers customers to track, receive alerts & monitor health of their tractors anytime, anywhere, enabling them to improve productivity and profitability. Digi Sense truly stands testimony to Mahindra's commitment of designing Technology for Progress. 1. Live Tracking 2. Vehicle status 3. Battery not charging alert 4. Low fuel alert 5. Air filter clog alert 6. High engine temperature alert 7. Clutch over ride alert 8. Engine running hours 9. PTO running hours

10.Vehicle speed

VARIOUS PARTS IN TRACTOR: 1. PTO: Power take-off (PTO) is a device that transfers an engine’s mechanical power to another piece of equipment.

2. TRUMPET / REAR AXLE

3. BOW TYPE FRONT AXLE Better tractor balance in Agri operations and ease and consistent turning motion.

4. HYDRAULIC LIFT: -

Based on pascal’s law.

Manufacturing Facilities A number of manufacturing facilities are available at the Mahindra and Mahindra, Mahindra Division, Plant -1 The whole manufacturing system is divided into a number of departments 1.Light machine shop 2.Heavy machine shop 3.Paint shop 4.Assembly shop 5.Heat treatment shop 6.Quality Engineering Light Machine shop All shaft, gears, bushes which are used in tractors are manufactured here. Most of machines are of HMT (for gear shaver) and German (for bevel gear) Machines are used in LMS: 1. Planer machine 2. Hand lathe 3. Universal milling machine 4. Grinding machine 5. Hydraulic press 6. CNC machine Manufacturing Operations:  Facing

 Under cutting  Chamfering  Finish turning  Grooving  Knurling  Broaching  Drilling  Boring  Grinding  Shaping Component Machined in shop:  Bull pinion shaft  Bull pinion  Gears  Idler cluster  Input shaft  Intermediate shaft  Lay shaft  Internal gears  Bushes Heavy Machine shop All heavy casting of tractor machined in this shop. The major operation carried out are milling, boring, tapping, champhering, finishing etc. Types of machine:  Radial drilling machine  Hergebret machine  Vertical milling machine

 Horizontal milling machine  Lathe  Double end boring machine  Automatic lathe  SPM (special purpose machine) Component machined in H.M.S:  Differential housing  Gear box  Trumpet housing  Rear axle Paint shop Paint Shop is the place where the different sheet metal components are painted. They are made to pass through various chemicals before they are actually painted. The painting method opted is that of Spray Painting. The paint shop at the plant is equipped with the washing and drying facility for the engine and transmission section of the plant as well as the sheet metal components of the tractor. Heat Treatment shop Heat treatment shop plays a very important role in every industry. In automobile industry all the gear and shafts need to be heat treated to impart desired strength and increase life of the component. The Heat Treatment shop at plant is equipped with several gas carbonizing furnaces, quenching tanks, induction hardening machines and shot blasting furnaces. All the gears and shafts that have been manufactured in the plant are heat treated before they are ready to be installed in the tractor. Assembly shop The Assembly line at Mahindra Tractor division deals with the assembly of tractor models 585 DI,575 DI,475 DI,415 DI, 275 DI,265 DI, etc. Assembly is the joining of

various constituents to form a final product. The assembly process is carried out on the main line, which has various sub-assemblies along its length. Assembly shop can be divided in two main areas: 1) Before paint area 2) After paint area.

Before paint area The area before painting can further be divided into sub-assemblies/ loops namely a) Differential loop. b) Gearbox loop. c)Rear cover loop. d)Engine assembly loop. Differential Assembly loop In the differential loop, the differential casting is mounted on trolley after washing and left and right Bull pinion Shaft is fitted. Then the Cage assembly consisting of Crown Wheel is fitted. Tall pinion assembly, Roller bearing, PTO shaft, Rear axle/trumpet, PTO shifter assembly, Gear box assembly, Rear cover assembly, Brakes, Parking brake, Suction pipe, PTO cover, Trailer hook, Angle bracket, Rocket link, Footboard and Clutch pedal is fitted. Gearbox loop In the gear box loop, the Gearbox housing mounted on trolley, Drive shaft, input shaft ,output shaft , Lay shaft, connecting shaft assembly, Shifter rod assembly, Steering assembly are assembled. Rear cover loop In the rear cover loop Rear cover mounted on trolley. Control valve and response valve assembly, Ram assembly are fitted. Engine Assembly loop

In the engine loop the Engine mounted on trolley, Dynamo, Self-motor, Oil pump, Front axle beam and bracket and Clutch plate is fitted. After that the chassis is carried to the next level by the lift where the engine & the 3-pointassembly of the tractor along with the other components are fixed. The parts fitted here are: 3-point linkage which contains the following parts:  Bracket.  Lower link fitted at the left side  Levelling rod fitted at the right side.  Stabilizer stainer.  Draw bar.  Top link.  Battery frame.  Front frame.  Tie rod attached with the drop arm of the steering system.  Accelerator link.  Delivery pipe.  Engine attachment. The engine is attached with the chassis system in this level of assembly. The engine is also carried to this level with the help of the lift crane, which lifts the engine assembly & delivers it to this level. Shlug is applied at the corner or we can say at the circumference of the gearbox where engine is attached with studs & bolts. Shlugs works as gaskets or seals & avoid the oil leakage and water mixing in the engine. Then the engine and chassis system, mounted on the cover system enter the paint shop area, where it is washed, dried and painted. The engine and chassis assembly after the paint shop reach here, and gets fitted with following parts:

 Front axle.  Extension in the front axle used for the setting of the wheels.  K.P.S.A. (King Pin Shaft Axle) with the wheel disc & nuts fitted in there for the fitting of the wheels.  Drop arms.  Tie rods.  Bucket.  Clutch plates  Alternator.  Self-starter.  Fuel pump. Then the whole assembly is mounted over the conveyor, which takes that piece to different chambers of washing, drying, premiering, baking, painting & again baking. The chassis and the engine going for washing and drying and then it goes to the paint shop.

After paint area After painting the conveyor takes the assembled piece to the Dismounting stage where different parts & components like tyres, radiator, dashboard, sheet metal parts, seating, steering wheel, etc are fitted on the tractor & the tractor was completed. After that the

testing of the tractor is done. A tractor has to pass through different tests to claim itself to be worthy to be sold and if there is some problem coming out in this stage, the tractor is sent to the recovery shop, where the problem of the tractor is recovered. After the recovery the tractor is again tested & after passing the test the tractor finally sends to the yard from where it is dispatched after Pre-dispatch inspection (PDI).

Quality Engineering Auditor: Quality engineers may be responsible for auditing their own companies or their suppliers for compliance to international quality standards such as ISO9000 and AS9100. They may also be independent auditors under an auditing body. Process quality: Quality engineers may be tasked with value stream mapping and statistical process control to determine if a process is likely to produce defective product. They may create inspection plans and criteria to ensure defective parts are detected prior to completion. Supplier quality: Quality engineers may be responsible for auditing suppliers or performing root cause and corrective action at their facility or overseeing such activity to prevent the delivery of defective product. PRE-DELIEVERY INSPECTION

In the industry, a pre-delivery inspection is "the final check carried out by the dealer on a car before they hand it over to you", and includes various checks to ensure that the vehicle is up to a certain standard before it is presented to the purchaser.

Conclusion: - I have learnt about the Tractor assembly and its parts and mechanism. In other word I learnt how industries work.