The document summarizes the process for manufacturing a clutch bell at Scooters India Limited. The process begins with shearing steel sheet in the press shop (Line 12) to form strips. The strips then undergo blanking and drawing, re-striking, and piercing and embossing operations in the press shop. Next, the parts are heat treated in Line 05 before being phosphated in Line 14. The parts then return to the machining shop (Line 08) for inspection. Finally, the clutch bells are assembled into the gearbox and engine, which are then assembled into the final vehicle. The document provides details on the equipment, materials, and processes used in each manufacturing line.

1. 1
ACKNOWLEDGEMENT
The success of any project depends largely on the encouragement and
guidelines of many people who have directly or indirectly worked on
the project. We sincerely acknowledge our gratitude to a host of
personalities with those support, guidelines and encouragement, the
present final thesis has been materialized.
Firstly, I would like to thank SCOOTER INDIA LIMITED, for
providing an excellent facilities and infrastructure required for
carrying out the project.
Our sincere thanks to my guide Mr. S.M. Vishwakarma , and the staff
of SIL who helped me at every stage of this project.
I also owe a debt of gratitude to Prof. KAMAL SHARMA (GLA
UNIVERSITY, MATHURA) for encouraging me for completion of
this project.
Last but not the least, a big thank to my family members and friends
for being supportive and being instrumental in the successful
completion of this project.

2. 2
CERTIFICATION
This is to certify that the project entitled
“MANUFACTURING AND ASSEMBLY OF
CLUTCH BELL” is a bonafide record of the Summer
Training doneby “AVINASH SINGH” in a partial
fulfillment of the requirements for the award of
B.TECH in “MECHANICAL ENGINNERING” at the
“SCOOTERS INDIA LIMITED” is an authenticwork
carried out by him undermy supervision and guidance.
Date-
Mr. S.M.Vishwakarma
Deputy Manager
Tool Room
Scooters India Limited

3. 3
DECLARATION
I AVINASH SINGH hereby declare that the work
which is been presented in dissertation entitled,
”MANUFACTURINGAND ASSEMBLY OF
CLUTCHBELL” in partial fulfillment of the
requirements for the award of the degree of
“BACHELOR OF TECHNOLOGY” , “GLA
UNIVERSITY”, MATHURA is an authenticrecord of
my own work during the period of days from 31st
May
2016 to 28th
June 2016 underthe supervision of
Mr.S.M. Vishwakarma , Deputy Manager (Tool Room)
SCOOTERS INDIA LIMITED, Lucknow.
The matter embodied in this dissertation has not been
submitted by me for any other award of any other
degree or diploma.
Date-
Avinash Singh
G.L.A. University
Mathura.

4. 4
CONTENTS
SR.
NO.
TOPICS PAGE NO.
1 HISTORY- SIL 06-08
2 ABSTRACT 09
3 SAFETY AND PRECAUTION 10-11
4 FLOW CHART FOR FULL PROCESS 12
5 FLOW CHART FOR
MANUFACTURING
13
6 PRESS SHOP (LINE NO.12) 14-21
7 MACHINING SHOP (LINE NO.08) 22-36
8 HEAT TREATMENTSHOP (LINE NO
05)
37-42
9 PHOSPHATING SHOP (LINE
NO.14)
43-46
10 INSPECTION SHOP (LINE NO.08) 47
11 GEAR ASSEMBLY 48
12 ENGINE ASSEMBLY 49
13 VEHICLE ASSEMBLY 50
14 BIBLIOGRAPHY 51

5. 5
HISTORY OF SCOOTER INDIA
Incorporated in 1972, Scooters India Limited is an ISO 9001:2000 Company, situated at 16
Km mile stone, South-west of Lucknow, the capital of Uttar Pradesh on NH No 25 and is well
connected by road, rail and air.
It is a totally integrated automobile plant, engaged in designing, developing, manufacturing
and marketing a broad spectrum of conventional and non-conventional fuel driven 3-
wheelers.
Company’s plant owes its origin to M/s. Innocenti of Italy from which it bought over the
plant and machinery, design, documentation, copyright etc. The company also possesses the
world right of the trade name LAMBRETTA / LAMBRO.
In 1975, company started its commercial production of Scooters under the brand name of
Vijai Super for domestic market and Lambretta for overseas market. It added one more
wheel to its product range and introduced three wheelers under the brand name of
VIKRAM/LAMBRO. However, in 1997, strategically, the company discontinued its two-
wheeler production and concentrated only on manufacturing and marketing of 3 wheelers.
These three wheelers have become more relevant in the present socio-economic
environment as it transports goods and passengers at least cost.
The company has its own marketing network of Regional Sales Offices all over India, catering
to customer’s requirements in the areas of sales and services.
DEPARTMENTS
The organization has various departments to perform different activities competently. SIL
has an organized system to control different activities. Personnel & administration
department looks after the employees’ welfare, medical benefits, conveyance facilities,
maintains their personal records and controls their regularity. It also takes care of the
security for the organization. Marketing & services department looks after the marketing of
the products, provide services to the customer and regulates the activities in its various
regional offices.
Materials control the purchasing of the raw material, keep an eye on the cost of the
material in the market, store the different materials and products and establish a company-
vendor relationship. Workshop manufactures different products in steps in different lines.
Design & development is the prime creative unit for the organization. It brings out some
brilliant design with modern technologies. Finance & accounts section keeps track on the
financial growth and the maintenance of various types of accounts.

6. 6
ASSEMBLY
The components manufactured in plant as well as those bought have to be finally assembled
to make the product three wheelers. In the process many sub assemblies, too, are involved.
However, two main assemblies worth mentioning are engine assembly and vehicle
assembly. Both are conveyorized. Every 5 minutes a three wheeler rolls down the conveyor.
The vehicle conveyor has 23 stations. Speed can be adjusted to meet increasing demand.
MACHINE SHOP
Machine shop has a wide variety of machines like General purpose machine, Special
purpose machine, Multispindle automatic machine, Single spindle automatic machine etc;
which are mainly working on single shift through eight different lines. Line no 2 is basically
machining the aluminium components. Crank shaft and cylinder machining is usually done
on line no 3. Line no. 4 is the Grinding line where the grinding process is done. Heat
treatment is performed in line no 5, while different turning of shafts and gear shaping and
shaving are carried on line no 6.Line no. 7 includes the functioning of gear manufacture
process mainly broaching, hobbing, finish turning, gear shaving etc. machining of different
levers, centre less grinding of tubes and shafts, serration / thread rolling operations is
achieved in line no. 8 & lastly different components are fed in two other lines by line no. 9.
Blank turning of gear and machining of parts is done on multi spindle and single spindle
automatic machine. Engine components and some vehicle component are the prime
production.
FABRICATION
The fabrication operations are carried out in two departments viz. Press Shop and Welding
Shop. The Press Shop is equipped with 20 presses ranging from 10 tons to 550 tons. Presses
are fed by sheets cut to size on shearing machines of 3000x6 & 2500x3 mm. size.
Components ranging from washer to cabin roof and door (1000x1200 mm.) are being
processed in this shop.
The Welding Shop is equipped with battery of Spot welding, MIG welding, Seam welding as
well as Arc welding machines. CO2 welding is extensively used for getting close tolerance on
welded structures. The department has its own auxiliary shop for maintenance of tools and
dies.

7. 7
PAINT SHOP
Paint shop includes three sections namely Paints section, spray phosphating section,
pickling. Paint section includes two convention painting spray booth & one electrostatic
painting plant. The first one is called conventional primer where mainly frame paintings are
done. The equipments used for conventional painting are Bullow's 230 spray guns and
pressure fit tanks (we prepare paints). The various types of frames like Diesel 750, Mini
petrol, Mini diesel, Diesel floor mounting, Diesel Nepal, Diesel scrubber, Electric vehicle are
painted here. The other conventional booth is known as conventional finish booth. Here the
frame accessories like cabin front, roof top, front fork, axle housing are painted. In
electrostatic plant the accessories of the frame, the component of lighter weight and
minimum size like silencer, pillar and various brackets are painted here.
In spray phosphating, the main work is to clean the components before painting or to make
surface according to paint requirement. After phosphating the products goes to passivation
for converting ferrous to ferric for paintings need. The products come from welding shop,
press shop and machine shop to phosphating, and after the process is being done the
products go to vehicle assembly. The pickling department is mainly for maintaining the
surface of heavily corroded materials.
FOUNDRY
The foundry, most modern in this part of the country, can produce all grades of grey cast
iron as well as S. G. iron. In fact, it had been innovative to find new processes of
modulisation, for which it was granted 2 patents. Equipped with an Induction Melting
furnace, Shell Moulding Machines & Core Shooters, Green Sand Moulding facilities,
Isothermal Heat Treatment Furnace, one sand Muller machine, two shot blasting machine,
two set jolting machines for green sand moulding, fettling and shot blasting equipments, its
normal range of production weighs up to 8 Kgs. on a pattern plate of 450x600 mm.
However, foundry men are trained to make casting even of 1 ton weight if emergent
requirement arises.
The foundry is not fully loaded with its captive requirement. Spare capacity is utilized for
producing sophisticated castings of prestigious customers like BHEL, Indian Railways,
Aerospace, Brakes India Limited, Crompton Greaves limited. The induction furnace has a
capacity of 1.3 tons. The two types of moulding is been done here.
1. Shell moulding
2. Green sand moulding.
The foundry can manufacture a wide range of products namely Differential housing,
Differential cages, Power transmission wheel, Crankcase flange, Magneto motor, Engine
output flange, Adapter plate for electric vehicle, Cylinder for both Vikram 410 petrol version
and Vikram 750 diesel version.

8. 8
SAFETY & PRECAUTIONS
1. Safety glasses, cover goggles, or face shields are required when in any shop area, whether
working or not!!
2. Shoes must be worn in any shop area. No one wearing sandals will be allowed to enter any
shop area. The minimum footwear must cover the entire foot.
3. Do not operate any item of equipment unless you are familiar with its operation and have
been authorized to operate it. If you have any questions regarding the use of equipment,
ask the area supervisor.
4. No work may be performed using power tools unless at least two people are in the shop
area and can see each other.
5. Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid
scattering chips. Never use compressed air guns to clean clothing, hair, or aim at another
person.
6. In case of injury, no matter how slight, report it to the shop supervisor. The campus
emergency phone number is 9-911.
7. Do not attempt to remove foreign objects from the eye or body. Report to the Sindecuse
Health Center (387-3287) for medical treatment. If chemicals get in the eye(s), wash eye(s)
for 15 minutes in an open flow of water before proceeding for medical treatment. In severe
cases, notify the Department of Public Safety at 387-5555.
8. Machines must be shut off when cleaning, repairing, or oiling.
9. Do not wear ties, loose clothing, jewelry, gloves, etc. around moving or rotating machinery.
Long hair must be tied back or covered to keep it away from moving machinery. Hand
protection in the form of suitable gloves should be used for handling hot objects, glass, or
sharp-edged items.
10. Wear appropriate clothing for the job (i.e., do not wear short sleeve shirts or short pants
when welding).
11. Do not work in the shop if tired, or in a hurry.
12. Never indulge in horseplay in the shop areas.
13. All machines must be operated with all required guards and shields in place.
14. A brush, hook, or special tool is preferred for removal of chips, shavings, etc. from the work
area. Never use the hands.
15. Keep fingers clear of the point of operation of machines by using special tools or devices,
such as, push sticks, hooks, pliers, etc. Never use a rag near moving machinery.

9. 9
FLOWCHART DEPICTING THE FULL PROCESS OF
MANUFACTURING AND ASSEMBLYOF CLUTCH
BELL
PRESS SHOP
↓
MACHINE SHOP
↓
HEAT TREATMENT SHOP
↓
PHOSPHETING SHOP
↓
MACHINE SHOP
↓
GEAR BOX ASSEMBLY
↓
ENGINE ASSEMBLY
↓
VEHICLE ASSEMBLY

10. 10
FLOWCHART DEPICTING THE PROCESS
REQUIREDIN THE MANUFACTURINGOF CLUTCH
BELL
LINE NO. 12 → PRESS SHOP
LINE NO. 08 → MACHINING SHOP
LINE NO. 05 → HEAT TREATMENT SHOP
LINE NO.14 → PHOSPHETING SHOP
LINE NO. 08 → INSPECTION

11. 11
LINE NO.-12
PRESS SHOP
 RAW MATERIAL:COLLED ROLLED STEEL SHEET (3mm).
 MACHINE/ES USED:
I. STAR GUILLOTINE SHEAR (SIMPLE DIE PRESS).
II. PRESS 110 TON KAUSHICO.
III. COMPOUND DIES FOR…
IV. SIMPLE DIES FOR…
 FLOW CHART DEPICTINGTHE OPERATION PERFORMEDDURINGTHE
PROCESSESINGOFCLUTCH BELL IN LINE NO. 12:
SHEARING INTO STRIPES
↓
BLANK AND DRAW
↓
RESTRIKING
↓
PIERCING ONE HOLE OF ø35 , FIVE HOLES OF ø10 & FIVE HOLES
OF ø4.1mm RESPECTIVELY
↓
EMBOSSING 5 OFF SEATS OF ø15.5mm for SPRING
↓
FLATENNING IF REQUIRED

12. 12
I. OBJECTIVE:TO CUT THE GIVEN WORKPIECE INTO STRIPS (SHEARING OF STRIPS).
 APPARATUS/MACHINE USED: SIMPLE DIE PRESS. (STAR GUILLOTINE SHEAR).
 MATERIALUSED: COLD ROLLED SHEET (3mm)
WHAT IS A CR SHEET(COLLED ROLLED SHEET)? WHAT PROPERTIES DOEES IT POSSES?
Cold Rolled Sheet are made up of a mixture of …..
Cold rolled steel sheets offer a variety of outstanding properties, including easy formability
and a smooth, clean surface, and are used in automobiles, appliances, furniture, and many
other everyday items.
 BLANK SIZE: L(1250)×128×3 mm3.
125×128×3 mm3(single piece dim.).
 TERMINOLOGIES/OPERATIONS:
 SHEARING: Shearing is the process of cutting off of sheets using a die and punch,
applying shear stress along the thickness of the sheet. A die and punch or a pair of blades
are used in shearing. Shearing happens by severe plastic deformation locally followed by
fracture which propagates deeper into the thickness of the blank. The clearance between
the die and punch is an important parameter which decides the shape of the sheared edge.
Large clearance leads to rounded edge. The edge has distortion and has burr. The shearing
load is also higher for larger clearance. For harder materials and larger sheet thickness,
larger clearances are required. Generally, clearance can vary between 2% and 8% of the
sheet thickness. Usually shearing begins with formation of cracks on both sides of the blank,
which propagates with application of shear force. A shiny, burnished surface forms at the
sheared edge due to rubbing of the blank along the shear edge with the punch or the die
wall. Shear zone width depends on the speed of punch motion. Larger speed leads to
narrow shear zone, with smooth shear surface and vice-versa. A rough burr surface forms if
clearance is larger. Similarly, a ductile material will have burr of larger height. Shearing a
blank involves plastic deformation due to shear stress. Therefore, the force required for
shearing is theoretically equal to the shear strength of blank material. Due to friction
between blank and tool, the actual force required is always greater than the shear strength.
Variation of punch force during shearing process is shown below. The maximum force
required on the punch for shearing can be empirically given as:
Fmax = 0.7tL
t - blank thickness
L - the length of the sheared edge.
For reducing the shearing force, the cutting edges of the punch are made at an angle. This
ensures cutting of a small portion of the total length of cutting.

13. 13
 PRINCIPLE:
A punch (or moving blade) is used to push the workpiece against the die (or fixed blade),
which is fixed. Usually the clearance between the two is 5 to 40% of the thickness of the
material, but dependent on the material. Clearance is defined as the separation between
the blades, measured at the point where the cutting action takes place and perpendicular to
the direction of blade movement. It affects the finish of the cut (burr) and the
machine's power consumption. This causes the material to experience highly localized shear
stresses between the punch and die. The material will then fail when the punch has moved
15 to 60% the thickness of the material, because the shear stresses are greater than
the shear strength of the material and the remainder of the material is torn. Two distinct
sections can be seen on a sheared workpiece, the first part being plastic deformation and
the second being fractured. Because of normal in homogeneities in materials and
inconsistencies in clearance between the punch and die, the shearing action does not occur
in a uniform manner. The fracture will begin at the weakest point and progress to the next
weakest point until the entire workpiece has been sheared; this is what causes the rough
edge. The rough edge can be reduced if the workpiece is clamped from the top with a die
cushion. Above a certain pressure the fracture zone can be completely eliminated. However,
the sheared edge of the workpiece will usually experience work hardening and cracking. If
the workpiece has too much clearance, then it may experience roll-over or heavy burring.
STAGES OF SHEARING OPERATIONS
 TOOL MATERIALS:
1. Low alloy steel is used in low production of materials that range up to 0.64 cm (1/4 in)
thick.
2. High-carbon, high chromium steel is used in high production of materials that also
range up to 0.64 cm (1/4 in) in thickness.
3. Shock-resistant steel is used in materials that are equal to 0.64 cm (1/4 in) thick or
more.
 TOLERANCES AND SURFACE FINISH:
When shearing a sheet, the typical tolerance is +0.1 or -0.1, but it is feasible to get the
tolerance to within +0.005 or -0.005. While shearing a bar and angle, the typical tolerance is
+0.06 or -0.06, but it is possible to get the tolerance to +0.03 or -0.03. Surface finishes

14. 14
typically occur within the 250 to 1000 microinches range, but can range from 125 to 2000
microinches. A secondary operation is required if one wants better surfaces than this.
 PROCEDURE:
1. Select the die to be used for the operation of SHEARING.
2. Take the CR sheet and put it on the press with the help of machine
(Hydraulic/pneumatic Cranes).
3. Start the press and perform the task.
4. The sheet is cut into 125×128×3 mm3 dimensional small pieces.
II. OBJECTIVE:TO PERFORM BLANKING AND DRAWING OPERATION ON THE GIVEN
WORKPIECE AFTER SHEARING OPERATION.
 APPARATUS/MACHINE USED: PRESS 110 TON KAUSHICO (COMPOUND DIE).
 MATERIALUSED: COLLED ROLLED SHEET STRIPS (125×128×3 mm3)
 TERMINOLOGIES/OPERATIONS:
 BLANKING:
Blanking is a metal fabricating process, during which a metal workpiece is removed
from the primary metal strip or sheet when it is punched. The material that is removed is
the new metal workpiece or blank.
Characteristics of the blanking process include:
 Its ability to produce economical metal workpieces in both strip and sheet metal
during medium or high production processes,
 The removal of the workpiece from the primary metal stock as a punch enters a
die,
 The production of a burnished and sheared section on the cut edge,
 The production of burred edges,
 The control of the quality by the punch and die clearance,
 The ability to produce holes of varying shapes – quickly.
The blanking process forces a metal punch into a die that shears the part from the larger
primary metal strip or sheet. A die cut edge normally has four attributes. These include:
 burnish
 burr

15. 15
 fracture
 roll-over
The illustration that follows provides a two-dimensional look at a typical blanking process.
Note how the primary metal workpiece remains and the punched part falls out as scrap as
the punch enters the die. The scrap drops through the die and is normally collected for
recycling.
Like many other metal fabricating processes, especially stamping, the waste can be
minimized if the tools are designed to nest parts as closely together as possible.
The illustration that follows shows the workpieces that could be created through the
blanking process using either sheet or roll as the parent material.
The blanking process has some downside effects. These include:
 Generating residual cracks along the blanked edges,
 Hardening along the edge of the blanked part or workpiece, and
 Creating excess roll-over and burr if the clearance is excessive.
The most common materials used for blanking include aluminum, brass, bronze, mild
steel, and stainless steel. Due to its softness, aluminum is an excellent material to be
used in the blanking process.
 DRAWING:

16. 16
Drawing operation transform flat sheets of metal into cups, shells or other drawn shapes by
subjecting the material to severe plastic deformation. Shown in fig is a rather deep shell that
has been drawn from a flat sheet.
Drawing tool and die
This type of Press tool is used to perform only one particular operation therefore classified
under stage tools.
 PROCEDURE:
I. Select the compound die to be used for the operation of BLANKING & DRAWING.
II. Take the stripes one by one and put it on the press manually.
III. Start the press and perform BLANKING operatin on it.
IV. Then take the workpiece(the circular piece blanked out from the stripe of ɸ119mm)
and now perform DRAWING operation on it by striking it to the Die.
V. Remove the worpiece from the press and move it to the shop for next operation.
III. OBJECTIVE: TO RESTRIKE THE WORKPIECE FOR SMOOTHNESS AND TO DEFORMANY
IRREGULARITIES ON THE SURFACE.
 APPARATUS/MACHINE USED: PRESS 110 TON KAUSHICO (SIMPLE DIE).
 MATERIALUSED: COLLED ROLLED WORKPIECE FROMPREVIOUS STEP.
 TERMINOLOGIES/OPERATIONS:
 RESTRIKE:
RESTRIKE operation is carried on the drawn workpieces from flat sheet of steel into cups.
This process is required to deform any irregularities on the surface and also the surface
smoothness so that it can be fit for other operation to be performed on it. It is again
redrawn into the same shell by applying force to perform the RESTRIKE OPERATION.

17. 17
 PROCEDURE:
I. Select the simple die press to be used for the operation of RESTRIKING.
II. Take the workpiece one by one and put it on the press manually.
III. Start the press and perform RETRIKE operatin on it.
IV. Remove the worpiece from the press and move it to the other shop for next
operation.
IV. OBJECTIVE:TO PERFORM THE OPERATION OF PIERCING ONE HOLE OF ø35 , FIVE HOLES
OF ø10 & FIVE HOLES OF ø4.1mm RESPECTIVELY.
 APPARATUS/MACHINE USED: PRESS 110 TON KAUSHICO (SIMPLE DIE).
 MATERIALUSED: COLLED ROLLED WORKPIECE FROMPREVIOUS STEP.
 TERMINOLOGIES/OPERATIONS:
 PIERCING:
Piercing is a shearing process where a punch and die are used to create a hole in sheet
metal or a plate. The process and machinery are usually the same as that used in blanking,
except that the piece being punched out is scrap in the piercing process.
There are many specialized types of piercing: lancing, perforating, notching, nibbling,
shaving, cutoff, and dinking.
The amount of clearance between a punch and die for piercing is governed by the thickness
and strength of the work-piece material being pierced. The punch-die clearance determines
the load or pressure experienced at the cutting edge of the tool, commonly known as point
pressure. Excessive point pressure can lead to accelerated wear and ultimately failure.
Burr height is typically used as an index to measure tool wear, because it is easy to measure
during production.

18. 18
For simple piercing operations a pancake die is used.
 PROCEDURE:
i. Select the simple die press to be used for the operation of PIERCING.
ii. Take the workpiece one by one and put it on the press manually.
iii. Start the press and perform PIERCING operatin on it.
iv. Remove the worpiece from the press and move it to the other shop for next
operation.
V. OBJECTIVE:TO PERFORM THE OPERATION OF EMBOSSING 5 OFF SEATS OF ø15.5mm for
SPRING.
 APPARATUS/MACHINE USED: PRESS 110 TON KAUSHICO (SIMPLE DIE).
 MATERIALUSED: COLLED ROLLED WORKPIECE FROMPREVIOUS STEP.
 TERMINOLOGIES/OPERATIONS:
 EMBOSSING:
Sheet metal embossing is a process for producing raised or sunken designs or relief in sheet
metal. This process can be made by means of matched male and female roller dies, or by
passing sheet or a strip of metal between rolls of the desired pattern. It is often combined
with Foil Stamping to create a shiny, 3D effect.

19. 19
 PROCESS:
The metal sheet embossing operation is commonly accomplished with a combination of
heat and pressure on the sheet metal, depending on what type of embossing is required.
Theoretically, with any of these procedures, the metal thickness is changed in its
composition.
Metal sheet is drawn through the male and female roller dies, producing a pattern or design
on the metal sheet. Depending on the roller dies used, different patterns can be produced
on the metal sheet. The pressure and a combination of heat actually "irons" while raising
the level of the image higher than the substrate to make it smooth. The term "impressing"
refers to an image lowered into the surface of a material, in distinction to an
image raised out of the surface of a material.
In most of the pressure embossing operation machines, the upper roll blocks are stationary,
while the bottom roll blocks are
Embossing machines are generally sized to give 2" of strip clearance on each side of an
engraved embossing roll. Many embossing machines are custom-manufactured, so there
are no industry-standard widths. It is not uncommon to find embossing machines in
operation producing patterns less than 6" wide all the way up to machines producing
patterns 70"+ wide.
 PROCEDURE:
I. Select the simple die press to be used for the operation of EMBOSSING.
II. Take the workpiece one by one and put it on the press manually.
III. Start the press perform EMBOSSING operatin on it.
IV. Remove the worpiece from the press and move it to the other shop for next
operation.

20. 20
LINE NO.-08
MACHINE SHOP
 RAW MATERIAL:COLLED ROLLED SHEET AFTER PERFORMED BY A SEVERAL NO. OF
OPERATIONS IN THE PRESS SHOP TAKEN TO THE NEXT SHOP.
 MACHINE/ES USED:
V. SPECIALPURPOSE M/C (FACING, GROOVING, BORING & CHAMPHERING).
VI. DOUBLE ENDED BORING M/C.
VII. VERTICAL BROACHING M/C.
VIII. 5 TON HYDRAULIC PRESS M/C.
IX. PEDASTAL GRINDER M/C.
X. PNEUMATIC BENCH GRINDER M/C.
XI. BENCH WITH FILE.
 FLOW CHART DEPICTINGTHE OPERATION PERFORMEDDURINGTHE
PROCESSESINGOFCLUTCH BELL IN LINE NO. 08:
FACING, BORING, GROOVING & CHAMFERING (INNER & OUTER).
↓
BROACHING TO FORM RADIAL SLOTS
↓
BROACH SLOT SIDES FORENLARGING FRONTEND & CHAMFERING (2 PCS AT
A TIME)
↓
DEBURR SLOTS FROM INSIDE AND OUTER DIAMETER
↓
DEBURR THE PART IN AND AROUND SLOTTED WALLS AND REMOVE
SHARP EDGES.

21. 21
I. OBJECTIVE: TO PERFORM THE OPERATION OF FACING, BORING, GROOVING &
CHAMFERING.
 APPARATUS/MACHINE USED:
i. SPECIAL PURPOSE M/C (FACING, GROOVING, BORING & CHAMPHERING).
ii. DOUBLE ENDED BORING M/C.
 MATERIALUSED: CR SHEET (3mm).
 TERMINOLOGIES/OPERATIONS:
A. TURNING:
TURNING is an engineering machining process in which a cutting tool, typically a non-
rotary tool bit, describes a helical toolpath by moving more or less linearly while the
workpiece rotates. The tool's axes of movement may be literally a straight line, or they
may be along some set of curves or angles, but they are essentially linear (in the
nonmathematical sense). Usually the term "turning" is reserved for the generation
of external surfaces by this cutting action, whereas this same essential cutting action
when applied to internal surfaces (that is, holes, of one kind or another) is called
"boring". Thus the phrase "turning and boring" categorizes the larger family of
(essentially similar) processes. The cutting of faces on the workpiece (that is, surfaces
perpendicular to its rotating axis), whether with a turning or boring tool, is called
"facing", and may be lumped into either category as a subset.
ADVANTAGES-
a) All materials compatible.
b) Very good tolerances.
c) Short lead time.
DISADVANTAGES-
a) Limited to rotational parts.
b) High equipment cost.
c) Significant tool wear.
d) Large amount of scrap.
e) Part may require several operation and machines.
APPLICATIONS-
a) Machine components, shafts, engine components.

22. 22
B. FACING:
FACING in the context of turning work involves moving the cutting tool at right angles to the
axis of rotation of the rotating workpiece.[1] 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 workpiece, and often the last—hence the
phrase "ending up".
ADVANTAGES-
I. After performing facing, the surface becomes smooth and well finished.
II. Short lead time.
III. Very good tolerances
DISADVANTAGES-
I. Limited to rotational parts.
II. Parts may require several operation and machines.
III. High equipment cost.
IV. Significant tool wear.
APPLICATION-
I. Machine components, shafts, engine components.

23. 23
C. GROOVING
GROOVING is like parting, except that grooves are cut to a specific depth instead of severing a
completed/part-complete component from the stock. Grooving can be performed on internal and
external surfaces, as well as on the face of the part (face grooving or trepanning).
D. BORING:
Enlarging or smoothing an existing hole created by drilling, moulding etc.i.e. the machining of
internal cylindrical forms (generating) a) by mounting workpiece to the spindle via a chuck or
faceplate b) by mounting workpiece onto the cross slide and placing cutting tool into the chuck.
This work is suitable for castings that are too awkward to mount in the face plate. On long bed
lathes large workpiece can be bolted to a fixture on the bed and a shaft passed between two lugs
on the workpiece and these lugs can be bored out to size. A limited application but one that is
available to the skilled turner/machinist.
ADVANTAGES- The following are the advantages of the boring-
a) All material compatible
b) Very good tolerance.
c) Low cost.
DISADVANTAGES- The following are the disadvantages of the boring operation-
a) The material at the bottom of the hole is disturbed by heavy tool.
b) Limited tooling design.
APPLICATIONS-
a) Widely used for manufacturing of the machine components and engine shafts.
b) Used in manufacturing of axle housing of various vehicle.

24. 24
E. CHAMFERING:
CHAMFERING is the operation of beveling the extreme end of a workpiece. This is done to
remove the burrs, to protect the end of the workpiece from being damaged and to have a
better look. The operation may be performed after knurling, rough turning, boring, drilling.
Chamfering is an essential operation before thread cutting so that the nut may pass freely on
the threaded workpiece.
ADVANTAGES- The following are the advantages of the chamfering operation-
a) Easy to assemble.
b) Flexible adjustment to the cross section.
c) Chamfers can be machined inside and outside.
DISADVANTAGES- Following are the disadvantages of the chamfering operation-
a) Greater accuracy and precision required.
b) Skilled labours are required for this operation.
c) Limited tooling design.
APPLICATIONS-
a) Chamfering is widely used in manufacturing for axle housing.
b) Used in the architech engineering.
 PROCEDURE:
 Select the m/c to be used to perform the operation of FACING, BORING, GROOVING &
CHAMFERING.
 Take the workpiece one by one and put it on the m/c manually.
 Start the m/c to perform FACING, BORING, GROOVING & CHAMFERING operatin on it.
 Remove the worpiece from the press and move it to the other m/c for next operation.

25. 25
II. OBJECTIVE: TO PERFORM THE BROACHING OPERATION TO BROACH TO FORMRADIAL
SLOTS AND BROACH SLOT SIDES FOR ENLARGING FRONT END & CHAMFERING (2 PCS AT A
TIME).
 APPARATUS USED: VERTICAL BROACHING M/C.
 MATERIALUSED: CR SHEET (3mm).
 TERMINOLOGIES/OPERATIONS:
 BROACHING:
Broaching is a machining process that uses a toothed tool, called a broach, to remove
material. There are two main types of broaching: linear and rotary. In linear broaching,
which is the more common process, the broach is run linearly against a surface of the
workpiece to effect the cut. Linear broaches are used in a broaching machine, which is also
sometimes shortened to broach. In rotary broaching, the broach is rotated and pressed into
the workpiece to cut an axis symmetric shape. A rotary broach is used in a lathe or screw
machine. In both processes the cut is performed in one pass of the broach, which makes it
very efficient.
Broaching is used when precision machining is required, especially for odd shapes.
Commonly machined surfaces include circular and non-circular holes, splines, keyways, and
flat surfaces. Typical workpieces include small to medium-sized castings, forgings, screw
machine parts, and stampings. Even though broaches can be expensive, broaching is usually
favored over other processes when used for high-quantity production runs.
Broaches are shaped similar to a saw, except the height of the teeth increases over the
length of the tool. Moreover, the broach contains three distinct sections: one for roughing,
another for semi-finishing, and the final one for finishing. Broaching is an unusual machining
process because it has the feed built into the tool. The profile of the machined surface is
always the inverse of the profile of the broach. The rise per tooth (RPT), also known as
the step or feed per tooth, determines the amount of material removed and the size of the
chip. The broach can be moved relative to the workpiece or vice versa. Because all of the
features are built into the broach no complex motion or skilled labor is required to use it. A
broach is effectively a collection of single-point cutting tools arrayed in sequence, cutting
one after the other; its cut is analogous to multiple passes of a shaper.
A push style 5
⁄16 inch (8 mm) keyway broach; note how the teeth are larger on the left end.
 PROCEDURE:
I. Select the m/c to be used to perform the operation of BROACHING.
II. Take the workpiece one by one and put it on the m/c manually.

26. 26
III. Start the m/c to perform BROACHING operatin on it.
IV. Remove the worpiece from the press and move it to the other m/c for next
operation.
III. OBJECTIVE: TO PERFORM THE OPERATION OF DEBURRING SLOTS FROM INSIDE OUTER
DIAMETER THE PART IN AND AROUND SLOTTED WALLS AND REMOVE SHARP EDGES.
 APPARATUS USED: PEDASTAL GRINDER.
PNEUMATIC BENCH GRINDER.
 MATERIALUSED: CR SHEET (3mm).
 TERMINOLOGIES/OPERATIONS:
 DEBURRINGPROCESS:
In wet applications the abrasive is applied as a slurry usually with water as the liquid, along
with rust inhibitors if required. The process is considered a precision method in that part
tolerance can be maintained.
 GRINDING(ABRASIVE CUTTING):
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.
A wide variety of machines are used for grinding:
 Hand-cranked knife-sharpening stones (grindstones)
 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding machines
 Bench grinders often found in residential garages and basements
Grinding practice is a large and diverse area of manufacturing and 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 cutting 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 thousandth of an inch or 12.7 μm.
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.

27. 27
 GRINDINGWHEEL:
A grinding wheel is an expendable wheel used for various grinding and abrasive machining
operations. It is generally made from a matrix of coarse abrasive particles pressed and
bonded together to form a solid, circular shape, various profiles and cross sections are
available depending on the intended usage for the wheel. Grinding wheels may also be
made from a solid steel or aluminium disc with particles bonded to the surface.
 LUBRICATION:
The use of fluids in a grinding process is necessary to cool and lubricate the wheel and
workpiece as well as remove the chips produced in the grinding process. The most common
grinding fluids are water-soluble chemical fluids, water-soluble oils, synthetic oils, and
petroleum-based oils. It is imperative that the fluid be applied directly to the cutting area to
prevent the fluid being blown away from the piece due to rapid rotation of the wheel.
Work
Material
Cutting Fluid Application
Aluminum Light duty oil Flood
Brass Light duty oil Flood
Cast Iron Heavy duty emulsifiable oil, light duty chemical oil, synthetic oil Flood
Mild Steel Heavy duty water soluble oil Flood
Stainless
Steel
Heavy duty emulsifiable oil, heavy duty chemical oil, synthetic oil Flood
Plastics
Water soluble oil, dry, heavy duty emulsifiable oil, dry, light duty
chemical oil, synthetic oil
Flood

28. 28
 PROCEDURE:
I. Select the m/c to be used to perform the operation of GRINDIND/DEBURRING.
II. Take the workpiece one by one and put it on the M/C manually.
III. Start the m/c to perform DEBURRING/GRINDING operatin on it.
IV. Use lubricants to cool the workpiece during deburring
V. Remove the worpiece from the press and move it to the other m/c for next operation.
IV. OBJECTIVE: TO PERFORM THE OPERATION OF FILING TO REMOVE THE BURR.
 APPARATUS USED: IN FILE.
 MATERIALUSED: CR SHEET(3mm).
 TERMINOLOGIES/OPERATIONS:
 FILING:
Filing is a material removal process in manufacturing. Similar, depending on use, to both
sawing and grinding in effect, it is functionally versatile, but used mostly for finishing
operations, namely in deburring operations. Filing operations can be used on a wide range
of materials as a finishing operation. Filing helps achieve workpiece function by removing
some excess material and deburring the surface. Sandpaper may be used as a filing tool for
other materials, such as glass.
 PROCEDURE:
I. Select the FLAT FILE tool to be used to perform the operation of FILING.
II. Take the workpiece one by one manually.
III. Perform FILING operatin on it.
IV. Remove the worpiece from the press and move it to the other m/c for next
operation.

29. 29
OPERATION SHEET NO.1
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DL VIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 50
OPERATION- FACE, BORE & GROOVE
MACHINE- DOUBLE ENDED BORING M/C.
MACHINE NUMBER- 2730
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF Ist
stage 2nd
stage
Rpm OF JOB 480 770
Cutting speed in m/min ø36-51 ø83-129 Ø36-82
travel of TOOL (in mm) 8 8 3
Feed in mm/min - - -
Feed in mm/rev 0.05 0.05 0.05
Depth of cut in mm - - -
OPERATORtime in sec. 15” 15”
OP. time in sec. 22 22 7
F/F time in sec. 81”
STD. time in sec. -
% efficiency -
m/c setting time/batch -

30. 30
OPERATION SHEET NO.2
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DLVIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 60
OPERATION- BROACH TO FORM RADIALSLOTS
MACHINE- VERTICALBROACHING M/C
MACHINE NUMBER- 2022
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF -
Rpm OF JOB -
Cutting speed in m/min 1.2
travel of TOOL (in mm) -
Feed in mm/min -
Feed in mm/rev -
Depth of cut in mm -
SETTING time in sec. 18’’
OP. time in sec. 45’’
F/F time in sec. 63’’
STD. time in sec. -
% efficiency -
m/c setting time/batch -
Lubricant -

31. 31
OPERATION SHEET NO.3
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DLVIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 70
OPERATION- BROACH SLOT SIDE FOR ENLARGING
FRONT END AND CHAMPERING (2 PIECESATA TIME)
MACHINE- 5 TON HYD. PRESS
MACHINE NUMBER- 3259
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF -
Rpm OF JOB -
Cutting speed in m/min 2.9
travel of TOOL (in mm) -
Feed in mm/min -
Feed in mm/rev -
Depth of cut in mm -
SETTING time in sec. 36’’
OP. time in sec. 89’’
F/F time in sec. 125’’
STD. time in sec. -
% efficiency -
m/c setting time/batch -
Lubricant -

32. 32
OPERATION SHEET NO.4
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DLVIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 80
OPERATION- DEBURR SLOTS ON OUTER DIA.
MACHINE- PEDASTALGRINDER
MACHINE NUMBER- 3731
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF -
Rpm OF JOB -
Cutting speed in m/min -
travel of TOOL (in mm) -
Feed in mm/min -
Feed in mm/rev -
Depth of cut in mm -
SETTING time in sec. -
OP. time in sec. 20’’
F/F time in sec. -
STD. time in sec. -
% efficiency -
m/c setting time/batch -
Lubricant -

33. 33
OPERATION SHEET NO.5
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DLVIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 81
OPERATION- DEBURR SLOTS ON INNER DIA.
MACHINE- PNEUMATIC BENCH GRINDER
MACHINE NUMBER- -
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF -
Rpm OF JOB -
Cutting speed in m/min -
travel of TOOL (in mm) -
Feed in mm/min -
Feed in mm/rev -
Depth of cut in mm -
SETTING time in sec. -
OP. time in sec. 20’’
F/F time in sec. -
STD. time in sec. -
% efficiency -
m/c setting time/batch -
Lubricant -

34. 34
OPERATION SHEET NO.6
SHEET NUMBER- 01
MODEL NAME- VIJAI SUPER 150 DLVIKRAM 410P
PART NAME- CLUTCH BELL
PART NUMBER- 43.02.0009
MATERIALSPECIFICATION- STEEL GR ‘DD’SKIN PASS IS : 4030
WT/PIECE(KG)- 0.359
OPERATION NUMBER- 82
OPERATION- DEBURR THE PARTIN AND AROUND
SLOTTED WALLSAND REMOVE SHARP EDGES
MACHINE- BENCH
MACHINE NUMBER- -
LINE NUMBER- 08
DATA OF MACHINING
Rpm OF -
Rpm OF JOB -
Cutting speed in m/min -
travel of TOOL (in mm) -
Feed in mm/min -
Feed in mm/rev -
Depth of cut in mm -
SETTING time in sec. -
OP. time in sec. -
F/F time in sec. 25’’
STD. time in sec. -
% efficiency -
m/c setting time/batch -
Lubricant -

35. 35
LINE NO.-05
HEAT TREATMENT SHOP
 RAW MATERIAL:
I. COLLED ROLLED SHEET (3mm).
II. ALKALI SOLUTION (WATER + CARDOCLEAN).
III. LPG.
IV. CO2 GAS.
V. OIL/BRINE SOLUTION (QUENCHING).
 MACHINE/ES USED:
I. WASHING M/C.
II. DRIER/DRYING MACHINE.
III. SEALED QUINCHED FURNACE M/C.
IV. SEALED QUINCHED TEMPERING M/C.
 FLOW CHART DEPICTINGTHE OPERATIONSPERFORMEDDURING
THE PROCESSESINGOFCLUTCH BELL IN LINE NO. 05:
WASHING OPRATION
↓
HEAT TREATMENT (CASE HARDENING)
↓
WASHING OPRATION
↓
TEMPERING

36. 36
I. OBJECTIVE: TO PERFORMTHE WASHING OPERATION ON THE WORKPIECE TO REMOVE
FOREIGN MATERIAL CLEAN THE SURFACE FOR GOOD CASE HARDENING LATER.
 APPARATUS/MACHINE USED: WASHING M/C.
DRIER/DRYING M/C.
 MATERIALUSED: COLLED ROLLED STEEL WORKPIECE FROMPREVIOUS STEP.
 TERMINOLOGIES/OPERATIONS:
 ALKALI DIP:
In this process we just dip the workpiece into the alkali solution so that the surface could
react to it and clean the surface
TIME OF DIP: 15-20 Mins.
TEMPERATURE OS ALKALI SOLUTION: 60-80°C
 ALKALI SPRAY:
In this process we spray the alkali solution on the workpiece so that the surface could react
to it and clean the surface
TIME OF SPRAY: 15-20 Mins.
TEMPERATURE OS ALKALI SPRAY: 60-80°C
 DRIER:
In this operation the workiece is sent to a furnace of higher temperature so as dry out the
solution from the surface of the workpiece
DRYING TIME: 20-45 Mins.
DRIER TEMPERATURE: 100-120°C
 PROCEDURE:
I. Take the workpiece and put it on the washing m/c conveyer.
II. Firstly dip the workpiece in the alkali sol.(WTER + CARBOCLEAN) for about 15-20
mins and at a temperature of about 60-80°C.
III. Secondly spray the alkali sol.(WTER + CARBOCLEAN) for about 15-20 mins and at a
temperature of about 60-80°C on the workpiece.
IV. Then use the Drier for about 20-45 mins at a temperature of about 100-120°C to
DRYOUT the workpiece and remove any amt. of alkali sol. present on the surface
of the workpiece so that it could not do any harm when CASE HARDENING is done
on it.
V. Remove the worpiece from the press and move it to the other shop for next
operation.

37. 37
II. OBJECTIVE: TO PERFORMHEAT TREATMENT (CASE HARDENING) ON THE WORKPIECE
TO IMPROVE ITS MECHANICAL & CHEMICAL PROPERTIES BY INTRODUCING CARBON BY
DIFFUSION PROCESS TO A CASE DEPTH OF 0.25mm.
 APPARATUS/MACHINE USED: SEALED QUINCHED FURNACE M/C.
 MATERIALUSED: COLLED ROLLED STEEL (3mm) WORKPIECE FROM PREVIOUS STEP.
 TERMINOLOGIES/OPERATIONS:
 HEAT TREATMENT:
HEAT TREATMENT is a group of industrial and metalworking processes used to alter
the physical, properties of a material. The most common application is metallurgical. Heat
treatments are also used in the manufacture of many other materials, such as glass. Heat
treatment involves the use of heating or chilling, normally to extreme temperatures, to
achieve a desired result such as hardening or softening of a material. Heat treatment
techniques include annealing, case hardening, precipitation
strengthening, tempering and quenching. It is noteworthy that while the term heat
treatment applies only to processes where the heating and cooling are done for the specific
purpose of altering properties intentionally, heating and cooling often occur incidentally
during other manufacturing processes such as hot forming or welding.
 CASE HARDENING:
Case hardening is a thermochemical diffusion process in which an alloying element, most
commonly carbon or nitrogen, diffuses into the surface of a monolithic metal. The resulting
interstitial solid solution is harder than the base material, which improves wear resistance
without sacrificing toughness.
Laser surface engineering is a surface treatment with high versatility, selectivity and novel
properties. Since the cooling rate is very high in laser treatment, metastable even metallic
glass can be obtained by this method.
A modern, fully computerised case hardening furnace.

38. 38
The Rockwell hardness scale used for the specification depends on the depth of the total
case depth, as shown in the table below. Usually hardness is measured on the Rockwell "C"
scale, but the load used on the scale will penetrate through the case if the case is less than
0.030 in (0.76 mm). Using Rockwell "C" for a thinner case will result in a false reading.[25]
For cases that are less than 0.015 in (0.38 mm) thick a Rockwell scale cannot reliably be
used, so file hard is specified instead. File hard is approximately equivalent to 58 HRC.
When specifying the hardness either a range should be given or the minimum hardness
specified. If a range is specified at least 5 points should be given.
o CASE DEPTH : 0.25mm.
o HARDNESS REQUIREMENT: 79-81 HRA.
o TEMPERATURE OF THE OPERATION: 900-920°C.
o FAN STOP: 30 Mins.
o ENRICH: 45 Mins.
o CARCON POTENTIAL: 0.90-0.85-0.80.
o LPG FLOW: 2-2.5 LPM.
o CO2 FLOW: 1-1.2 LPM.
o DIFFUSION: 20 Mins.
o SECONDARY TEMPERATURE: 820-840°C.
o SECONDARY TEMPERATURE OPERATING TIME: 20 Mins.
o QUENCHING TEMPERATURE: 60-70°C
Rockwell scale requiredfor variouscase depths
Total case depth, min.[in] Rockwell scale
0.030 C
0.024 A
0.021 45N
0.018 30N
0.015 15N
Lessthan 0.015 "File hard"

39. 39
 QUENCHING:
Quenching is a process of cooling a metal at a rapid rate. This is most often done to produce
a martensite transformation. In ferrous alloys, this will often produce a harder metal, while
non-ferrous alloys will usually become softer than normal.
To harden by quenching, a metal (usually steel or cast iron) must be heated above the upper
critical temperature and then quickly cooled. Depending on the alloy and other
considerations (such as concern for maximum hardness vs. cracking and distortion), cooling
may be done with forced air or other gases, (such as nitrogen). Liquids may be used, due to
their better thermal conductivity, such as oil, water, a polymer dissolved in water, or
a brine. Upon being rapidly cooled, a portion of austenite (dependent on alloy composition)
will transform to martensite, a hard, brittle crystalline structure. The quenched hardness of
a metal depends on its chemical composition and quenching method. Cooling speeds, from
fastest to slowest, go from fresh water, brine, polymer (i.e. mixtures of water + glycol
polymers), oil, and forced air. However, quenching a certain steel too fast can result in
cracking, which is why high-tensile steels such as AISI 4140 should be quenched in oil, tool
steels such as ISO 1.2767 or H13 hot work tool steel should be quenched in forced air, and
low alloy or medium-tensile steels such as XK1320 or AISI 1040 should be quenched in brine.
 PROCEDURE:
I. Take the workpiece and put it on the SEALED QUINCHED FURNACE M/C conveyer.
II. The temperature of the furnace is about 900-920°C and then the fan is stopped fo 30
mins.
III. All the operations are done and then quenching is done.
IV. Remove the worpiece from the press and move it to the other shop for next
operation.
V. Again perform the washing operation.
III. OBJECTIVE: TO PERFORMTEMPERING OPERATION ON THE WORKPIECE TO INCREASE
ITS TOUGHNESS AND RELEAVE STRESSES.
 APPARATUS/MACHINE USED: SEALED QUINCHED TEMPERING M/C.
 MATERIALUSED: COLLED ROLLED STEEL WORKPIECE.
 TERMINOLOGIES/OPERATIONS:
 TEMPERING :Tempering is a process of heat treating, which is used to increase
the toughness of iron-based alloys. Tempering is usually performed after hardening, to
reduce some of the excess hardness, and is done by heating the metal to some temperature

40. 40
below the critical point for a certain period of time, then allowing it to cool in still air. The
exact temperature determines the amount of hardness removed, and depends on both the
specific composition of the alloy and on the desired properties in the finished product. For
instance, very hard toolsare often tempered at low temperatures, while springs are
tempered to much higher temperatures.
TIME REQUIRED FOR OPERATION: 2 HOURS.
COOLING: AIR COOLLED.
 PROCEDURE:
I. Take the workpiece and put it on the SEALED QUINCHED TEMPERING M/C conveyer.
II. Do the operation for nearly 2 hours.
III. Air cool it.
IV. Remove the worpiece from the press and move it to the other shop for next
operation.

41. 41
LINE NO.-14
PHOSPHETING SHOP
 RAW MATERIALS:
I. DEGREASING SOLUTION.
II. PHOSPHORIC ACID (30 ml/lt).
III. NORMAL, SOFT & DOMESTING WATER.
IV. SODIUM BISULPHATE (25 gm/lt).
V. PHOSPHATING (30/40 ml/lt).
VI. CHROMIC ACID (20 gm/lt)
 MACHINE/ES USED:
I. LIFTING CRANES.
II. PUMPS.
 FLOW CHART DEPICTINGTHE OPERATIONSPERFORMEDDURING
THE PROCESSESINGOFCLUTCH BELL IN LINE NO. 05:
DEGREASING
↓
WR1 (NORMAL WATER)
↓
WR2 (NORMAL WATER)
↓
DR1 (DE-RUSTING TANK)
↓
DR2 (DE-RUSTING TANK)
↓
WR3 (NORMAL WATER)
↓
WR4 (NORMAL WATER)
↓
ACTIVATION TANK (SOFT WATER)
↓
PHOSPHATING TANK (DOMESTIC WATER)
↓
WR5 (DOMESTIC WATER)
↓
WR6 (NORMAL WATER)
↓

42. 42
PASSIVATION TANK (CHROMIC ACID)
↓
DRYING OF OVEN
 STEPS FOR CLEANINGIN PHOSPHATINGPLANT-
The workpiece is passed through various number of tanks followed by water tanks, which
allows that the result of one chemical does not affect the result of the other following
chemical tanks.
Therefore, below are following arrangement of the tanks for the complete cleaning process
or
a) Degreasing tank; followed by 2 water tanks.
b) De-rusting tank; followed by 2 water tanks.
c) Activation tank;
d) Phosphating tank; followed by 2 water tanks.
e) Passivation tank
f) Dry off oven
 DEGREASING-
TEMPERATURE- 40-50°C
Solvent degreasing is a process used to prepare a part for further operations such as
electroplating or painting.
It is a process in which a cleaning agent is applied directly to the surface by spraying,
bushing, or wiping. This process removes oil, grease, dirt, loose particles and any other
contaminants that may exist on the material.
a) SPRAYING; the most common cold solvent operation, this is usually small
maintenance degreasers using a petroleum or mineral solvent.
b) IMMERSION; the part is immersed in a tank of solvent and usually agitated like a
washing machine for clothes to get all of the contaminant off. Soaking is typically the
most common process. The material is left to soak until all the dirt are removed from
the surface.
DESIGN CONSIDERATIONS-
BENEFITS –
a) The emissions are reduced when compared with vapor degreasing operations.
b) Liquid solvent are safer to deal with than vapor degreasing agents.
c) Not as much venting is required, so it is easier to quickly set up a small degreasing
operation.

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CHALLENGES-
a) There is a high danger of fire when using petroleum and mineral solvents.
b) The emission from this type of operation, although less than those of other
operations, are still considerable, and solvent degreasing has an environment
impact.
c) Solvent are difficult to dispose of, and there are many government regulation on
them.
 DERUSTING-
CHEMICAL USED- phosphoric acid (30 ml/lt).
TEMPERATURE- 40-50°C.
This derusting process removes only the rust from the parts- all other exposed metal along
with their tolerance will not be affected. Afterwards, all types of rust inhibitors are applied
to the parts for rust protection.
The total derusting process uses no harsh acids and leaves no powder residue on the parts.
Once again, all shapes and sizes are accommodated packaged to the customer’s
specifications. All services are performed with quick turn around and utilizing
environmentally friendly methods.
 ADVANTAGES OF PHOSPHORIC ACID-
The following are the advantages of using phosphoric acid-
a) It will provide corrosion resistance of phosphate coating.
b) No toxic fumes.
c) No handling hazards.
d) Produces coating of low thickness but higher weights is ideal for better paint
adhesion.
 ACTIVATION PROCESS-
CHEMICAL USED: SODIUM BISULPHATE (25 gm/lt).
The activation tank is used widely for the cleaning purpose. Activation tank helps material to
activate the workpiece for the further processing.Which activates the surface of the
workpiece and helps to get ready for the painting purpose.
This type of cleaning process is not followed by water tanks because if water tanks is used it
will again wash the surface will which reduce the affect of activating chemicals.
 PHOSPHATINGPROCESS-

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Phosphate coating are used on steel parts for corrosion resistance, lubricity, or as a
foundation for subsequent coating or painting.
It serves as a conversion coating in which dilute solution of phosphoric acid and phosphate
salts is applied via spraying or immersion and chemically reacts with the surface of the part
being coated to form a layer of insoluble, crystalline phosphate.
 PROCESS-
The application of phosphate coating makes use of phosphoric acid and takes advantages of
the low solubility of phosphates in medium or high pH solutions. Iron, zinc or manganese
phosphate salts are dissolved in the solution of phosphoric acid. When steel or iron parts
are placed in the phosphoric acid, a classic acid and metal reaction takes place which locally
depletes the hydronium ions, raising the pH, and causing the dissolved salt to fall out of
solution and be precipitated on the surface. The acid and metal reaction also creates iron
phosphate locally which may also be deposited.
The acid and metal reaction also generates hydrogen gas in the form of tiny bubbles that
adhere to the surface of the metal. These prevent the acid from reacting the m0etal surface
and slows down the reaction.
 USES-
Phosphate coating are often used to provide corrosion resistance, however, phosphate
coating and their own do not provide this because the coating is porous.
 PASSIVATION PROCESS-
CHEMICAL USED- Chromic acid (20 gm/lt)
I. This process is just opposite of activation process.
II. This process is imposed on the work material to avoid the reaction of the work
material from the external environment.
III. Hence it deactivate the surface of the work material and helps the surface to get
ready for the painting process.
 DRYINGPROCESS-
TEMPERATURE- 120±5 °C
In this process the work material is kept in the DRY OFF OVEN, which helps the surface to
get dry, because if the surface is not dried the paint which is being applied on the surface
will not get attached properly. Hence it is applied for proper adhesion of the paint.

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LINE NO.-08
INSPECTION
 RAW MATERIALS: CR STEEL SHEET (3mm).
 APPARATUS/MACHINESUSED:
I. GAUGES FOR INSPECTION
 FLOW CHART DEPICTINGTHE OPERATIONSPERFORMEDDURING
THE PROCESSESINGOFCLUTCH BELL IN LINE NO. 08:
RECTIFICATION USING SUITABLE GAUGES
↓
FINAL INSPECTION

46. 46
FLOW CHART DEPICTING THE PROCESS
REQUIRED IN THE ASSEMBLY OF
CLUTCH BELL
GEAR BOX ASSEMBLY
↓
ENGINE TO GEAR BOX ASSEMBLY
↓
VEHICLE ASSEMBLY

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GEAR BOX ASSEMBLY
Following are the steps which is been followed for the GEAR BOX assembly of the CLUTCH
BELL-
1. AT FIRST THE INNER LEVER IS INSTALLED IN THE GEAR BOX HOUSING.
2. THEN GEAR COLLECTOR SHAFT AND LAY SHAFT IS INSTALLED.
3. THEN LAY SHAFT SPACER IS INSTALLED IN WITH DAVEL PIN.
4. GEAR SET OF 4 ARE THEN INSTALLLED ON LAY SHAFT AND A GEAR BOX FLANG IS
INSTALLED WITH A PARTICULAR CLEARANCE BTW THE GEARS WHICH HOLDS DOWN
THE GEAR AND ALL THE THINGS TOGETHER.
5. NOW PT WHEEL (POWER TRANSFER WHEEL) IS INSTALLLED ON THE GC SHAFT.
6. CLUTCH BELL IS INSTALLED ON IT WITH A TORQUE CLUSTER GEAR NUT .
7. A UMBRELLA FLANG IS INSTALLED ON IT HAVING SPRING IN BTW AND ONTO IT A SET
OF 8 PTATES (4 CORK + 4 STEEL) ARE INSTAALED AND THEN LOCKED SO THEY CAN
NOT MOVE FREELY.
8. THEN A REVERSE GEAR IS INSTALLED ON THE O/P SIDE.
9. NOW TOP CVER GAS KIT,TOP COVER, O RING , COMPANION FLANG & NUT ARE
INSTALLEG.
10. O RING, SPRING & R G LEVER IS INSTALED AND THE ASSEMBLY IS COMPLETED.
ENGINE- GEAR BOX ASSEMBLY
Following are the steps which is been followed for the ENGINE-GEAR BOX assembly.
1. ENGINE IS BROUGHT UP TO THE ASSEMBLY.
2. ENGINE O/P GEAR IS INSTALLED.
3. 50 TO 60 ml OF OIL NO. 40 IS USED TO FILL THE JUNCTION AS IT WORKS AS A
LUBRICANT AND MAKES THE ASEEMBLY SMOOTH TO PERFORM.
4. U P GEAR IS INSTALLED NOW.
5. A SEAL OF RUBBER IS INTRODUCE AND THEN GEAR BOX IS JOINED TO THE ENGINE
SO AS TO AIR TIGHT IT .

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VEHICLE ASSEMBLY
Following are the steps which is been followed for the Complete assembly of the VEHICLE.
1. HERE THE JOURNEY OF CLUTCH BELL END’S BY ASSEMBLING ENGINE WITH
THE CHASIS.
2. OTHER PARTS HENCEFORTH INSTALLED AND AFTER THAT A FINAL INSPECTION IS
DONE OF THE VEHICLE.

49. 49
BIBLIOGRAPHY
a) Automotive Mechanics – by William H. Crouse & Donald L.
Anglin
b) Theory Of Machines- by S.S.Ratna.
c) Internal Combustion Engines- by V.Ganeshan
d) Through Google (www.google.com)
e) Through Wikipedia(www.wikipedia.com)
f) YAHOO Answer.