PROJECT TITLES AS NEW MACHINE INSTALLATION

1. 6 MONTHS INDUSTRIAL TRAINING
REPORT
AT
MAHINDRA AND MAHINDRA
SWARAJ,MOHALI
SUBMITTED BY
SHASHI BHUSHAN
UE149077
SUMITTED TO
MR.TUKESH SONI

2. INTRODUCTION
-Established on 27 June 1970
-PTL started with annual capacity of 5000 tractors
and with a capital of 3.7 cores
-IN 2007 M&M(the leaders in domestic tractor
industry) acquired majority stake in PTL
-IN 2012 it changed to MAHINDRA AND
MAHINDRA SWARAJ LTD and it became second
tractor company to win ‘THE DEMING PRIZE’

3. IN 2013 swaraj division plant 1and plant 2 won TPM
Excellence award from JIPM
Location:- The factory is located at Sahibzada Ajit
Singh Nagar, an important industrial town in
Punjab, 5 km from Chandigarh
PTL consist of three divisions:
• Swaraj Tractor Division (STD), Mohali.
• Swaraj Foundry Division (SFD) ,Mazri.
• Swaraj Combine Division (SCD),
Chapparcheri.CHAPPAR

5. VARIOUS DEPARTMENT IN SWARAJ TRACTOR
DIVISION

6. LIGHT MACHINE SHOP (L.M.S)
L M S is the largest section of the factory. All
transmission components like shafts and gears used
in tractors are manufactured here. L.M.S comprises
of 117 machines.
• FUNCTION OF THE DEPARTMENT
• Gear manufacture and grinding.
• Machining of bull gears.
• Bevel gear cutting of all rounds on power hacksaws.
• Facing and centering.
• All type of grinding inner and outer gears.
• Hobbing and broaching machine.
•.

7. Gear shaving gear deburring machine.
• Drilling of all gears reporting system.
• Number of workmen shifts operations
Machines used in LMS:-
1.Planer machine
2.Hand Lathe
3.Universal Milling Machine
4.Grinding Machine
5.Hydraulic Press

9. HEAVY MACHINE SHOP (H.M.S)
• All heavy casting of tractors is machined in this
shop with the help of variety of special machine.
• Facilities of this shop include general-purpose
turning, drilling and milling machines
COMPONENTS MACHINED IN THE HMS
GEAR BOX HOUSING
DIFFERENTIAL HOUSING

10. REAR COVER
TRUMPET HOUSING
BRAKE HOUSING

11. HEAT TREATMENT SHOP
• In automobile industry all the gear and shafts need to be
heat treated to impart desired strength and increase life of the
component.
• The H.T shop at PTL is equipped with several gas
carbonizing furnaces, quenching tanks, induction hardening
machines and shot blasting furnaces.
WHY
Improve mach inability.
• Relieve internal stresses.
• Improve mechanical properties such as ductility,
strength ,hardness, toughness etc.
• Change in grain size.
• Increase resistance to heat and corrosion

12. ASSEMBLY SHOP (ASSEMBLY OF
SWARAJ TRACTOR)

13. • ASSEMBLY:
The process of joining various constituents to form
a final product.
Assembly of the tractor is divided into five sections:
a) Differential Sub assy.
b) Engine Sub assy.
c) Hydraulic rear cover Sub Assy.
d) Gearbox Sub Assy.
e) Main line Assy.

14. DIFFERENTIAL SUB ASSEMBLY
• FUNCTION:
When the vehicle takes turns , a device is necessary
which make the wheels move at different speed and
equal speed on straight path
To accomplished this purpose a system of gear
called “Differential System “ is provided.

15. CAGE
ASSEMBLY
CAGE , BULL
GEAR &BRAKES
FIITTED
PTO SHIFTER &
SUCTION AND
STRAINER ASSY
BRAKE PEDAL
,TAIL PINION
SHAFT FITTED
GEAR BOX
COUPLING
LAY OUT OF DIFF.
SUB ASSY

16. LAY OUT OF ENGINE SUB ASSY
HYD PUMP
ASSEMBLY
CLUTCH PLATE
&
PRESSURE
PLATE
FITMENT
ALTERNATOR
,STARTING
MOTOR
FITMENT
FRONT AXLE
BEAM
ASSEMBLY
KING PIN
STUB AXLE
ASSEMBLY
FRONT AXLE
BEAM
FITMENT

17. 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 methods operated is that of Spray painting.
NEED FOR
PAINTING:-
• Long Life.
• Rust Resistance.
• Better Look

18. The various operation performed in paint shop
are
• Surface Preparation (Pre Treatment Cell) – carried out
for sheets and rims.
• Painting JOSH 1(dash board, rear frame ,front shield
,top bonnet),JOSH 2(fenders, side panel), CHASSIS
BOOTH (washing, primer,washing zones), FINAL TOUCH
UP.
• Inspection.
• Rejection (Reprocessing) for sheets and rims
• NEED FOR SURFACE PREPERATION
For removing Organic compounds (oil, grease)
• Inorganic compounds (oxides, peroxides)
• Better paint adhesion.
• Elimination chances of reoccurring of dust.

19. MY PROJECTS
INSTALLATION OF NEW
MACHINCE

20. INSTALLATION OF NEW MACHINCE
IS IT EVEN A PROJECT
ANY WORK THAT IS
DONE IN INDUSTRY
IS A SORT OF
PROJECT BCOZ IT
HAS TO BE
CARRIED WITH
ATMOST
SAFETY,PLANED
METHOD AND
CALCULATION
MACHINCE IS A
COMBINATION
OF LINKS JOINED
BY NO. OF
JOINTS.SO TO
RUN AMACHINCE
ALL THE LINKS
MUST BE
INSTALLED
PROPERLYSO
THAT IT CAN
WORK PROPERLY

21. INTRODUCTION
STARRAG IWK 7000
IT IS A GERMAN TECHNOLOGY MACHINCE BUILT WITH
THE INCORPATION WITH INDIAN ENGINEERS,THE I
STANDS FOR INDAIN

22. INTRODUCTION AND CHARACTERSTICS
THE IWK 7000 MACHINCES ARE HIGH PERFORMANCE 4 AXIS
HORIZONTAL MACHINING CENTRES DESIGNED FOR INTRICATE AND
COMPLEX MACHINCING OF FERROUS AS WELL AS NON FERROUS
COMPONENTS PROVIDING HIGH FLEXIBILITY,PERFORMANCE AND
CONSISTENT PERFORMANCE
CHARACTERSTICS
NUMBER OF AXES 4
SPINDLE ORIENTATION HORIZONTAL
X TRAVEL 910 MM
Y TRAVEL 800 MM
Z TRAVEL 1000 MM
ACCURACY 10 MICRONS

24. ROTATIONAL SPEED
MIN 20RPM
MAX 6000 RPM

26. WHY IT WAS BROUGHT
1. VARIOUS OPERTIONS LIKE DRILLING,BORING,TAPPING ,
MILLING,FACING
2. INCREASED THE PRODUCTION
3. REDUCED HUMAN EFFORT AS IT IS FULLY AUTOMATIC
4. IT PROMISED LONG TERM ACCURACY,LONG TEM
RELIABILITY AND LONG TERM PRODUCTIVITY

27. KEY BENEFITS AND TECHANICAL DATA
1) RIGID STRUCTURE
2) HIGH TORQUE GEARED SPINDLE HSKA100
3) HEAVY DUTY TOOL HANDLING SYSTEM
4) RUGGED ROLLER GUIDEEWAYS
5) ACCURATE CLAMPING
6) PALLET-FIXTURE INTERFACE LOCATION
TECHANICAL DATA
1. CLAMPING SURFACE 630X630 MM
2. W/P INTERFACE AREA DIA. 1100 MM
3. MAX. FEED 50 M/MIN
4. SPINDLE TAPER HSKA100
5. TORQUE TORQUE 733 NM
6. POWER 22 KW
7. MAX. TOOL WEIGHT 25KG

28. MAX.TOOL SLOTS 120

29. INSTALLATION PROCESS
1.TRANSPORATION PROCESS
 STARRAG IWK 7000 IS VERY BULKY MACHINCE .IT
REQUIRES VERY PRECISE HANDLING METHOD.
THE MACHINCE WAS FIRST TRANSPORTED FROM
BANGALORE TO MOHALI VIA ROAD I.E BY TRUCKS.IT WAS
PACKED IN VERY LARGE CARTON
JCB CRANES WERE USED TO LIFT WOODEN CARTON
FROM THE TRUCK AND BE PLACED ON THE GROUND

31. DEASSEMBLING AND MAINTENANCE
PHASE

34. AFTER BEING TRANSPORTED,THE MACHINCE WAS
DISASSEMBLED SO THAT EACH PART CAN BE CHECKED
THROUGHLY FOR ANY DAMAGE,
PROBLEM
ENCOUNTERED
1) EYE BOLT OF ONE OF THE PART WAS DAMAGED .SO THERE WAS
A NEED TO DESIGN A M30 EYE BOLT.SO THIS TASK WAS GIVEN
TO ME.SO I DESIGNED IT AND GAVE DRAWING TO ASSEMBLY
SHOP AND THEY MADE IT

36. ELECTRICAL PHASE
Main tasks carried out:
1.Visual inspection of the main cable terminals
2Checking of the cooling and lubricating systems
3Electrical measurement and check of all the machine´s wiring
4Testing and calibrating setup parameters like Automatic
Voltage Regulation (AVR) setting, Checking the idle running,
load running and connecting the generator phases to the grid
Checking the operating parameters – load sharing, checking
operating temperatures and vibrations

37. SETTING OF STABILIZER
This system stabilizes the input voltage to be stable and
generates a reliable output voltage
TECHANICAL PARAMETERS
1. POWER RANGE 100KVA
2. INPUT RANGE 360V
3. OUTPUT RANGE 415V
4. COOLING AIR/OIL
5. EFFICIENCY >95%
6. WORKING FREQUENCY 50-60 HZ
BASIC PARTS
Cabinet; English, LCD display screen
Terminals: 3 phase 4 wires (With Neutral Ground/Earth);
Main Switch, AC contactor, Servo Motor, Carbon
Brush, Cables/Busbar, PCB main board, Manual/Automatic Switch,
Adjusting transformer (contact type voltage regulator),

38. LEXOS 100
KVA
STABILIZER

39. MECHANICAL PHASE
MECHANICAL PHASE START WITH THE ASSEMBLY OF ALL PARTS
LIKE MAGAZINE,STABILIZER,HYDRAULIC POWER
PACK,PALLETS,TOOL SPINDLE
THE MOST IMPORTANT PART OF THIS PHASE IS TO INSTALL
HYDRAULIC POWER PACK.THE FUNCTION OF THIS PUMP IS
CONVERT ELECRTICAL ENERGY TO MECHANICAL ENERGY.
GENERATING A DRIVING TORQUE,HYDRAULIC POWER UNITS
FUNCTION AS A POWER SOURCE.IT WILL BE CONNECTED TO
PALLET.IT IS ALSO USED FOR CLAMPING AND UNCLAMPING OF
TOOL SPINDLE

42. COMPLETELY INSTALLED STARRAG IWK 7000

43. FINAL PHASE:TESTING PHASE
1. AFTER THE MACHINCE IS INSTALLED THE FOREMOST STEP
IS TO CHECK PALLET POSITION WITH RESPECT TO THE
TOOL SPINDLE . THEY SHOULD BE IN STRAIGHT LINE,IT IS
DONE BY USING AN INSTRUMENT CALLED ‘LEVELS’’

44. 2. THEN TESTING OF DRILLS IS DONE FROM THE MAGAZINE WHICH
HOLDS NUMEROUS TOOLS,DRILLS ARE WASHED WITH COOLANT

45. 3.THE LAST STEP INCLUDES TEST RUN WITH A DUMMY
GEARBOX AND PRODUCES VARIOUS FUNCTIONS
:DRILLING,BORING,MILLING,SURFACE FINISHING AND
GIVING HIGH ACCURACY