1. A Project on manufacturing of Rear Wheel Drum
By
HEMAPRASATH
MECHANICAL ENGG. (B.TECH)
SRM UNIVERSITY
CHENNAI
To
Mr.ISHWAR PRASAD
MANAGER OF LINE-2
MACHINE SHOP
SCOOTERS INDIA LIMITED
LUCKNOW
SCOOTERS INDIA LIMITED
2. CERTIFICATE
This is to certify that this summer training report has been
prepared by HEMAPRASATH (B.TECH-MECH) from SRM
UNIV ERSITY , CHENNAI in the partial fulfilment of the
requirement of vocational training at SCOOTERS INDIA
LIMITED, LUCKNOW.
The matter was analysed by candidate under my guidance and
this report embodies the work done by him
We wish him a bright future
Guide
Ishwar Prasad
Manager
Machine shop line-2
3. Scooters India LTD
Lucknow
ACKNOWLEDGEMENT
At this very outset I sincerely acknowledge with
gratitude the guidance and support rendered to me by
Training Centre and Machine Shop Department of
Scooters India LTD without which this training would
not have materialized
I would like to thank Mr S.B.SINGH (H.R. SCOOTERS
INDIA LIMITED) for providing me an opportunity to
interact and take guidance from engineers of Machine
shop department.
During my summer training at Machine Shop I felt like
a family member and learn a lot about how a team
works to achieve the target, how industry works
towards continuous improvement in the direction of
the cost efficient, quality, customer satisfaction and
society at large.
4. I would like to thank Mr.IswarPrasad
(Dy.Manager,Machine Shop), and all engineers, staff
and workers of machine shop department, for
providing me proper guidance , site visiting , help and
other facilities makes my summer training very
interesting and easier.
Preface
Summer Training plays an important role in
engineering course as it give practical knowledge
of the things that we study theoretically in our
course.
It is my great pleasure in presenting the report
on manufacturing of Rear Wheel Drum and
suggests improvements based on observational
made at various stages of manufacturing, by the
learned fellow and faculty members of Scooters
India LTD, Lucknow
5. It also gives knowledge about total production
process and quality management and how
engineers work to utilize the resources properly
and efficiently
PRODUCT PROFILE
6.
7.
8.
9.
10.
11. ASSEMBLY:
Thecomponents manufacturedintheplant as well as
thoseboughthavetobefinallyassembledtomakethe
product three wheelers. In the process many sub-
assemblies too are involved. However, two main
assemblies
worth
mentioning
are engine
12. assembly and vehicle assembly. Both are
conveyorised. Every 5 mins a three wheelers rolls
down the conveyor. The vehicle conveyor has 23
stations. Speed can be adjusted to meet increasing
demand.
DICASTING:
Thebiggestdiecastingshopinthispartofthecountry
handles bothAluminiumandZinc alloys. Equippedwith
pressure die casting machines of 160,250,400 and
1000 tons locking pressure, the metal is fed to
machinesfromindividualholdingfurnaceof75/150kg,
13. Aluminiumcapacity.
The shop based on projected area, is capable of
producing aluminiumdiecasting upto5 kg inweight.
Theshopisbackedbychemicalsandmetallurgicallabs
as also with a die maintenance section. The well-
equipped machineries are used in two shifts that
produce all the accessories required by this
organization. The die casting of various types of
components like Gear box housing, Crankcase, Front
wheel drum, rear wheel drum, Bell housing, Magneto
flange,Cylinderhead,LowerandUpperhandlebar,
Levers, Differential housing cover, Brake shoe are
undertaken.
Die casting components for fulfilling customers
requirementarealsotakenup.Someofourcustomers
are BHEL, Bhopal, Greaves India Limited, Aurangabad
to whom supplying the Gear boxes and 422 cc
15. machines, Single spindle automatic machines etc.,
whichis mainly working onsingle shift thougheight
different lines. Line no. 2 is basically machining the
Aluminium components. Crankshaft and Cylinder
machining is usually doneonLineno. 3, Lineno. 4is
thegrinding linewherethegrinding process is done.
Heat treatment is performed in Line no. 5, while
different turning of shafts and gear shaping and
shaving arecarriedonLineno. 6 and7includes the
functioning of gear manufacturing process mainly
broaching,hobbing,finishing,turning,gearshavingetc.
Machining of different levers, centre less grinding of
tubes&shafts,threadrollingoperationsisachievedin
Lineno.9.Blankturningofgear&machiningofparts
Is done on multi-
spindle & single
spindle automatic
machine. Engine
16. components &some vehicle components are prime
productions.
FABRICATION:
The fabrication operations are carried out in two
department wise. Press shop & welding shop. The
press shopis equippedwith20presses rangingfrom
18. includes two conventions painting &spray booths &
one electrostatic painting plant. The 1st
one is called
conventional primepaintingareBulow230 spraygun
&pressurefit tanks. Thevarious types of frames like
diesel 750, mini petrol, mini diesel, diesel floor
mounting, diesel Nepal, diesel scrubber, electric
vehicle are painted here. The conventional booth is
known as conventional finish booth. Here the frame
accessorieslikecabinfront, rooftop, frontfrock, axle
housing is painted. In electrostatic plant the
accessories of the frame, the component of lighter
weight andminimumsizelikesilencer, pillar &various
bracketsarepaintedhere.
In spray phosphating the main is to clean the
component before painting or to make surface
accordingtopaint requirement. After phosphatingthe
20. FOUNDRY:
Thefoundry, most moderninthis part of thecountry,
canproduceallgradesofgreycastironaswellasSG
iron.Infact,ithadbeeninnovativetofindnewprocess
of modulation, for whichit was grantedtwopatterns.
Equipped with an induction melting furnace, shell
moulding machine & core scooter, green sand
facilities,isothermalheattreatmentfurnace,onesand
Muller machine, two shat blasting equipment, its
normal rangeof productionweight is upto8 kgona
patternplateof450×600mm.
The foundry is not fully loaded with its captive
requirements.Sparecapacityis utilisedfor producing
sophisticated casting of prestigious customer like
BHEL, Indianrailways, aerospace, brakes Indialimited,
Cromptongreaveslimited.
22. TOOL ROOM:
The tool roomis a cell where brain combines with
versatility to evoke the new era of invention. The
designs of tool coming from main tool planning
department are implementedhere. The tool roomis
furnishedwithwell-equippedmachineriesnamely- CNC
machine (Taiwan), Jig Boring machine (Czech
republic), Jig grinding machine (Switzerland), Profile
Grinding machine (Germany), Die sliding machine
(Czechrepublic),EDM(USA).
Toolroomevokeahighperformanceoutputconsisting
almost 99.9% of company’s requirement : One die
casting dieper year, 1-10 press tool per month, 8-10
jigs per month, 10-12 gauges per month &400 C.T.
toolspermonths.
23. These machines are
efficiently used to
manufacturing different
tools & dies like jigs &
fixtures, Gauges, Cutting tools, Forging dies, Die
casting dies, Developments Items etc. The different
activities like Turning, Milling different shapes,
Grinding, Heat treatment, Jig boring, Jig Grinding,
checking in the standard room, heat treatment
accordingtothejobrequirement, final inspectionare
undertakenintheinthetoolroom.
28. COMPONENTS:
Back Plate:
The Back Plate serves as the base onwhichall the
componentsareassembled.Itattachestotheaxleand
forms a solid surface for the wheel cylinder, brake
shoes and assorted hardware. Since all the braking
REAR WHEEL DRUM
29. operationexerts pressureonthebackplate, it needs
tobeverystrongandwearresistant.
Leavers for Emergency or parking brakes and
automatic brake shoe adjuster were also added in
recentyears.
Brake Drum:
TheBrakeDrumisgenerallymadeofaspecial typeof
cast iron which is heat conductive and wears
resistance. It is positioned very close to the brake
shoewithout actuallytouchingit, androtates withthe
wheelandaxle.
Wheel Cylinder:
Onewheelcylinderisusedforeachwheel.Twopistons
operate the shoes, one at each end of the wheel
30. cylinder.Whenhydraulicpressurefro
mthe master cylinder acts uponthe pistoncup, the
pistonsare
Pushedtowards the shoes, forcing themagainst the
drum.
Brake Shoe:
Brakeshoesaretypicallymadeoftwopiecesofsheet
steel weldedtogether. The frictionmaterial is either
rivetedtotheliningtableorattachedwithadhesive.
Automatic Self –Adjuster:
The self-adjuster is used to adjust the distance
33. STEPS INVOLVED IN MANUFACTURING
OF R.W.DRUM
1. IN DIE CASTING SHOP:
Machinethat isusedindiecasting shopis“HMT
BULLET 250Ton” adnois10041.
250Tonisthelockingpressureappliedduringthe
manufacturingofR.W.Drum.
Cast ironandsteel hubis usedfor manufacturing
of outer circular ring and inner circular ring
respectively.
DICOAT WATERWASTE AND DICOAT
34. 40(unchidova) is used to prevent sticking the
material tothedie.
Molten Aluminum alloy is used for its
manufacturingwhosemeltingpointisnearly
600°c, but in die casting shop it is heated up to
642°c.
Design provided in this structure so that it can
absorbtheexcessloadanddoesn’tgetaffected.
Pressure die casting is used for the whole
manufacturing, twotypesofdieisusedoneisfixed
andoneismoving.
Timelimits:
Timeformovingofpiston: 14sec
