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AN INDUSTRIAL TRAINING REPORT
DONE BY :
V.HEMA BHARGAVA REDDY
1021210115
B.TECH MECHANICAL
THIRD YEAR
AT
A-21 , SIPCOT Industrial Park , Oragadam , Sriperumbudur Taluk ;
Kancheepuram District - 602 105 , Tamil Nadu.
www.allisontransmission.com
SUBMITTED TO
FACULTY OF ENGINEERING &TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
SRM UNIVERSITY, KATTANKULATHUR
Kancheepuram Dist-603 203 Acknowledgement

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It is always a pleasure to remind the fine people in the Engineering program for their
sincere guidance I received to uphold my practical as well as theoretical skills in engineering.
Firstly I would like to thank Dr. C. Muthamizhchelvan (Director of E&T, SRM
University) for meticulously planning academic curriculum in such a way that students are not
only academically sound hut also industry ready by including such industrial training patterns.
I would also like to thank Mr. V.THIRUNAVAKKARASU (Class In-charge) for
the positive attitude he showed for my work, always allowing me to question him and giving
prompt replies for my uncertainties in all the fields including educational, social and managerial
work.
I express my immense pleasure and deep sense of gratitude to my guide
Mr. Karthikeyan .C for spending his valuable time with me and also helped me in completion
of task.
Bhargava Reddy

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CONTENTS
Introduction to Auto Transmission……………………....4
ALLISON Transmissions…………………….…………..6
Types of Gears Manufactured…………………………….7
Manufacturing flow process of Gears ……………………8
Role of Quality Department……………………………….10
CMM Lab…………………………………..………………11
Chemical lab………………………………………………13
Introduction to Assembly plant………………………….16
Transmission assembly flow process…………………….17
Tear down Assembly area……………………………......19
Working of Auto Transmission………………………….21
References……………………………………………….....23
Mini Project……………………………………………......20

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INTRODUCTION TO AUTO TRANSMISSION SYSTEM
The Transmission system in which the gear ratio changes automatically. Automatic
transmissions contain mechanical systems, hydraulic systems, electrical systems and computer
controls, all working together in perfect harmony. These Auto Transmissions are made by
arranging the Planetary Gears.
The major components in the Auto Transmission system are:-
Planetary Gear system
Torque convertor
Hydraulic system
Governor
Computer controls

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This plays a very predominant role in the working of Auto transmission.
Computer Controls:
 Detect such things as throttle position, vehicle speed, engine speed, engine load, etc. to
control exact shift points.
 Downshift automatically when going downhill, to control speed and reduce wear on the
brakes.
 Up shift when braking on a slippery surface to reduce the braking torque applied by the
engine.

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Allison Transmission
History:
Allison Transmission is the premier global provider of commercial
duty Automatic transmissions and hybrid propulsion systems. It was started in 1915 by
James Allison. Initially they manufactured Aircraft Engines and later switched to
Transmissions.
Allison products are specified by over 250 of the world’s leading vehicle manufacturers and are
used in many market sectors including bus, refuse, fire, construction, distribution, military and
specialty applications. Headquartered in Indianapolis, Indiana, Allison Transmission has regional
offices all over the world and manufacturing facilities in Indianapolis, Indiana and Szentgotthard
and Hungary.
The outer body is made up of Aluminium. Different materials like cast iron , plastic ,rubber, steel
are also used for various parts in the Transmission system.
Length : 600mm ; Breadth:250mm

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The Allison Transmission company includes two major processes to produce a single Auto
Transmission. They are :
Manufacturing of Gears
Fabrication and Assembly of Auto Transmission
The Unique feature that I absorbed in Allison Transmission making is that they have ERROR
PROOFING in almost all the processes.
I went through these processes and gained some knowledge . The systematic production process
which this company is following is excellent.
Now, I want to share what I have learnt from the Production and Assembly plants in my
training period.
The three types of gears which are majorly manufactured here are
Manufacturing of Gears
Pinion Gears Sun Gears Ring Gears
 1000 series 1000, 2000series 1000 series
 2000 series 3000 , 4000 series 2000 series
 3000 series 3000 series
 4000 series 4000 series
The major differences between the 1k, 2k, 3k & 4k series gears are diameter of the gear
, number of teeth and their RPM.
Depending on the type of transmission system these gears are used accordingly.
 Gleason Machines are used in this manufacturing of gears.
 Federal broach , Forst broach , Nagel Machines are also used.

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The flow process of 1000 & 2000 series Pinion gears is :
operation Inspection process
1. Washing
2. Hobbing PD gauge Roll checker Gear Analyser
3. Chamfering &
Deburring
4. Shaving PD gauge Roll checker Gear Analyser
5. Hardening Metallurgy lab Gear Analyser
6. Surface Grinding Inspection Gauges Gear Analyser
7. Honing Inspection Gauges Gear Analyser
8. Gear Burnishing Blue Test
9. Washing
10. Gear Roll checker Gear Analyser
11. Assembly
All the Inspection process is done by the Quality Department in "Metrology lab and shop
floor."
The manufacturing of the sun gears also follow all these operations. But, the Ring gears follow
different flow process when compared to the sun and pinion gears.

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Fire wall Inspection: This is done to check for the various defects in the gear like teeth
damage , cut mark , rust , incomplete weld , blow out , blow through , spatter , over bend , dent
, tool mark , shaving mark , under fill etc.... After this they will be sent to the packing area.
3K series Ring Gears 4K series Ring Gears
purchase pre-turned Gear Blank purchase pre-turned Gear Blank
Helical Broaching Hobbing
Parts washer External PD gauge
Hobbing Shaping
External PD gauge
Deburring process
Internal flank R/O
Internal PD gauge Part washing
Deburring process Heat treatment process
(Nitriding Process)
Heat treatment process
(Nitriding Process)
Assembly process
Assembly process

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After machining process the gears are sent to "Quality Department" which includes the
following labs :
1.Metrology lab.
2.Chemical lab.
3.CMM lab.
Metrology lab: In this lab different instruments are used to measure the different
parameters of the gears which are machined to get a product with
accurate measurements and good quality product.
The various instruments used to check various parameters of gears in this lab are:-
Instrument Resolution Purpose
 Comparator - 0.1micron - All types of plug gauge calibration.
 Bore Dial setter - 1micron - Bore Dial , Micrometer , vernier setting
 Gear Analyser - 0.1 micron - checking various parameters of gears
 Surface Finish Tester- 16 nm - checking surface finish
 Portable CMM - up to 1200mm - checking and analysing
 Optical comparator - To check various profiles in Gears & Blanks with
magnification 10X , 20X , 30X.
 Bore Video scope - To check the valves and holes in the Valve body
 Contour Tracer - To check the parameters of 1k & 2k series Ring gears
Note: Every parameter of the Gears has a spec value. The experimental value must
be within the tolerance . If the parameters are beyond the tolerance then the part is
rejected.
Lab Requirements :- Temp 200 to 250 c . Humidity - 40% to 60%
As, at 200 the thermal expansion the materials are very low.

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CMM Lab:- In this lab "Co-ordinate Measuring Machine" is used to measure
all the GD&T parameters of different parts of the Transmission.
Description of CMM: -
Model - ACCURA
Probe - ZEISS
Software - Calypso 5.0.24
Axis(x,y,z) - 6
X - Right to Left
Y - Forward & Rear
Z - Top to Bottom
Resolution - 0.1 micron
Repeatability - 2 microns (0.001mm)
Accuracy - 1.8+L/300 [L is length of specimen]

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The various parameters of the part checked by the CMM machine are:
 Roundness
 Roundness angle
 waviness
 Flatness
 Straightness
 Cylindricity
 True position
 Concentricity
 Co-axiality
 Perpendicularity
 Profile
 Line profile
 Parallelism
 Angularity
 Radial run out
 Axial run out
 curve form
The programs can be done for the following parts and checked by using CMM
1) Main case
2) Valve body main
3) Valve body shift

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4) Convertor Housing
5) Rear cover
6) Park Pawl
7) Park Pawl guide
8) Charging pump
9) P3 - Carrier
10) P2 - Carrier
11) P1 - Carrier
12) Front support
13) Front support assembly
The experimental values are compared with the spec values and they should be within
the tolerance limit. If not that parameter is detected by the software.
Chemical Lab:- In this lab the cleanliness of the Auto Transmission parts are
checked which are taken from the stores.
Requirements:
1. Weighing Balance Scale
2. PALL cleanliness machine
3. Pall filter paper of 10 microns
4. Techni clean AS-58 solution
5. Oven
At first , the machine is to be validated until you get the weight of the
filter paper below 0.5 mg

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Then place the child parts inside the pall chamber and start the cleaning
process by using the pistol .
The filter paper is attached to the vacuum pump which filters the dust
from the child parts. Then it is taken and place in the oven to take the
moisture from the filter paper.
Then the filter paper is weighed by using the weighing balance scale. It
should be within the Specification value provided to the specific part . If
not those parts are sent to the stores for re-washing. And after washing the
all parts from that slot again the same process is repeated.
The important thing is that only some parts of the Transmission system
are being checked by this process. The remaining parts are directly used
for assembly purpose.
After this process , the total quality department work is done and these
parts can be used for Transmission Assembly purpose.

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Parts for Cleanliness Test:
Child part sample specification(mg)
Valve Body shift 3 11
Valve Body main 3 11
Main case 1 22
Front support 3 25
Pump assembly body 3 15
Turbine shaft 3 15
Main shaft 3 13
Output shaft 3 13
Valve -Large (steel) 18 13
Valve -small( Aluminum ) 45 11
P1 carrier 3 15
P2 carrier 3 15
P3 carrier 3 15
Separator plate 6 12
Then the parts are sent with verified tag if there are no defects and
rejection tag if the measured values are beyond the specification values.

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ASSEMBLY OF 1000 & 2000 SERIES AUTO TRANSMISSIONS:
HIRATA machines are specially used for these assembly process. Both Hydraulic and
Pneumatic with Servo Motor machines are operated by using "Error Proofing"
system. So , there are very rare chances of missing the parts in the assembly process . So,
we will get a well assembled Auto Transmission.
The hydraulic machines are fully automated. Different kinds of cylinders are used for
operations like picking the part , fixing the part , and rotate the parts according to the
requirements , applying grease where ever necessary .
They follow different mechanisms for linear motion , vertical motion , rotating motion
and the speed of the machine vary according to the operation performed.
The complete program is already displayed on the screen. The operator must follow the
instructions and follow step by step procedure shown on the screen. If any step is missing
in the operation then the machine will not allow the assembly process to continue and
gives an alarm.
The speed of the hydraulic cylinders are maintained by the valves present at the each
cylinder. By adjusting the valves the speed of the machine can be varied.
The complete information of the transmission is stored in a small chip sensor which gives
the complete details about the transmission like it is present in which line, what kind of
operations are performed , exact location can also be traced.
If the Transmission is working well then Leakage test is done and then after final dressing
it will go to CARE AUDIT section where manual inspection will be done to check all
the parts of the transmission and then it is sent to the packing area.

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The Assembly flow process:
Main case
Rotating clutch
Front support
Convertor Housing
P1 Carrier
P2 Carrier
P3 Carrier
Rear cover
Seal & Sensor
Main valve body

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Control module sub Control Module Shift valve body sub
Filter & Oil pan
Torque Convertor
Function Testing (defects) Repair Area
Final Dressing
Leak Testing
Final Washing
Shipping
If the transmission is working properly in the function testing process it will go to for
final dressing or else it will be sent to "REPAIR AREA".

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Work at Repair Area : At the repair area , the total assembly is teared down
into parts and checked manually far any defects and then each & every part is
assembled in a systematic procedure by using the Kent tools. The torque of each and
every bolt must be checked and then check whether there are any defects and the oil is
also sent for testing purpose. While doing the assembly again we need to fix the torque
and fit the bolts.
The two types of wrenches used in this area are:-
o Dial type Torque checking wrench
o Click type Torque setting wrench
Some Main parts of the Auto Transmission along with Torque values:
Name of the part Setting Torque(N/m) Checking Torque
Filter Tube 25-35 27-50
Oil pan bolt 24-29 25-50
Valve body control module to main housing 10-13 8-17
Rear cover bolt(16 places) 51-61 43-77
Turbine speed sensor bolt 24-29 20 -37
Cooler port ship plug 2.5 - 5.5 2.5 - 5.5
Measure C5 clutch pack 1.54-2.69 1.54-2.69
PTO cover Bolt(12 places) 40-45 17-29
Output speed sensor bolt 10-13 8-17
Main pressure tap plug 10-13 9-23

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Name of the part Setting Torque(N/m) Checking Torque
Oil Filter 8.5-11.5 12-27
Shipping plate bolt 20-34 17-43
Convertor Housing to Front support 51-61 43-77
Convertor Housing to Main case 51-61 43-77
Depth of the Main pump input seal 0.0 - 0.40 0.0 - 0.40
Depth of Ground sleeve Bushing 0.0 - 0.25 0.0 - 0.25
Depth of Front support Bearing 0.0 - 0.25 0.0 - 0.25
Depth of Rotating clutch Bushing 0 - 0.5 0 - 0.5
These play a major role in the Auto Transmission
Planetary Gear systems - 3 [P1 , P2 , P3 Carriers]
Clutch Packs - 5 [C1 , C2 , C3 , C4 , C5 Clutches]
C1 - 7 Friction plates & 7 Reaction plates
C2 - 7 Friction plates & 6 Reaction plates
C3 - 4 Friction plates & 4 Reaction plates
C4 - 6 Friction plates & 6 Reaction plates
C5 - 6 Friction plates & 6 Reaction plates
Torque Convertor - Which takes the energy from the fly wheel connected to
engine.
Snap rings - To hold the clutches

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Thrust Bearings - To absorb the load
PARK -PAWL is present in the Transmission for the vehicles used in the hilly areas.
Gaskets (5) are used at different places to avoid the leakage of the oil.
Valve body connected with Internal mode space.
24 Pin connection is connected to TRANSFER CONTROL MODULE(TCM) which
is the "Brain of the Auto Transmission."
Working of the Auto Transmission:
At first the energy from the engine is transferred to the Torque convertor which are
connected by Fly wheel .
There is a Stator and Rotor in the Torque convertor . The rotor which will start rotating
due to the energy from the Engine and makes the Stator to rotate which makes the
turbine shaft rotate .
Then TCM which is connected to the main valve body operates the flow of the oil and
the clutch packs rotates along with the main shaft. The planetary gear systems also
rotates along with their respective clutch packs .
From this turbine shaft the energy is transferred to the differential and the wheels.
Inference: I came to know about the different manufacturing process of
Gears, the various inspection processes , and systematic flow
process of Auto Transmission assembly.

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I got some practical knowledge by seeing all the parts of the Transmission and could
find the differences between the Manual and Auto Transmission.
I understood the differences between the working of Auto & Manual Transmission.
I had a good working experience in the Tear down Assembly area.
The staff who helped be to gain all these stuff are:-
Mr. Nithya Mr. Karthikeyan
Mr. Aravindan Mr. Suresh kumar
Mr. Dannie Mr. Sarvanan
Mr. Vinoth Mr. Javeed
Mr. Gowri Mr. Gopi
Mr.Meganathan Mr. John
I thank all of u whole heartedly for sparing your valuable time to teach me and guide
me to improve my practical and theoritical knowledge.
I am so happy to be in Allison family for two weeks.
THANK YOU , THANK YOU VERY MUCH TO "ALLISON TRANSMISSONS."
References: WWW.ALLISONTRANSMISSIONS.COM
WIKIPEDIA

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Mini Project
Problem Statement - How to reduce the setting time for "INTRA ROLL
-CHECKER"
Analysing the Problem
Time consuming steps:
1.Changing the Arbor
2. Adjusting the conveyor belt
3.Changing the Gripper
4.Changing the Off sets
5.checking for the required parts offset
6.Adjusting the Stop block
It totally consumes 40 to 50 minutes to complete the setting process.

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Suggestions
Modifications that can be done to reduce the setting time :
Internal changes should be made to external
Threads of the screws can be reduced
We can use color codes for different part off sets.
Two steel plates can be arranged on both the sides of conveyor belt as in
the hobbing and shaving machines and adjust according to the required
diameter.
Result : By considering the above suggestions, the setup time can be reduced to 20
minutes.
As the setup time decreases, the output of the Intra Roll checker increases by checking different
types of gears within a short period of time.

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