This document is a project report submitted by Sayan Sarkar to the Department of Mechanical Engineering at Indian Institute of Engineering Science & Technology, Shibpur. The project involved studying the manufacture of vehicle frames at Tata Motors in Jamshedpur, including the assembly line, 5000 ton press, materials used, and processes involved. The author thanks various people at Tata Motors for their guidance and support during the project.

1. Manufacture of Frame with the study of Assembly
Line & 5000 Ton Press
SUBMITTED BY
SAYAN SARKAR
DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN INSTITUTE OF ENGINEERING SCIENCE & TECHNOLOGY,SHIBPUR

2. It is really a matter of great pleasure to acknowledge the invaluable guidance,
enormous assistance and excellent co-operation extended to me by TATA MOTORS
Jamshedpur in the completion of my project.
To start with, I would like to express my gratitude towards all the people who have
contributed their precious time and effort to help me in the project. I would like to
thank Mr. Ashok Kumar [ AGM ( Maintenance ), Jamshedpur Works, Frame Factory
] and Mr. Rakesh Cheeli [ Manager ( Maintenance), Jamshedpur Works, Frame
Factory ]; for their guidance, support, motivation and encouragement throughout
the project period.
Their readiness for consultation at all times, their valuable remarks, their concern
and assistance have been invaluable. I would also like to express my heartfelt
thanks to my friends and my project partner. Last but not the least; I would also
extend my sincere gratitude to Department of Mechanical Frame Factory, Tata
Motors Jamshedpur for availing the facilities required for my project analysis.
I also express my heartiest gratitude to all the people of Tata Motors for their
constant help and support. This work would not have been possible without the
support and help from them.

3. This is a project through which we have aimed to
achieve an understanding and learning of
development of a product straight from its
conception to manufacturing, encompassing all the
stages such as Initial Calculations, Designing,
Material Selection and Manufacturing
considerations.

4. To study of Decoiler and Straightner used for long member.
To study materials generally used for manufacturing long
member used in frame.
To study the processes taking place on Assembly Line.
To study the working of 5000 Ton Press ( Hydraulics ).
To study PTCED used in Frame Shop.
To study the processes taking place on Frame Line I, II and III.

5. Type of Steel Used Dimension ( in mm ) Application
E 46 Steel
7 X 388 Heavy Commercial
Vehicle
7 X 321 Light Commercial
Vehicle
7 X 362 Reinforcement
5 X 318 Light Commercial
Vehicle
• E 46 Steel Sheet required for the manufacture of Long Member is taken in
Coiled Form which is decoiled using Decoiler.
• Range of Long Member usually lies between 4m to 12m.

8. A frame is the main structure of the chassis of a motor vehicle

9. 5000T Press Long Member Packing and Despatch
Main Road
Pre Treatment Cathode Electrode
Depostion
Frame Assembly Line 1
Frame Assembly Line 2
Paint booth and
Baking oven
Walk Way
Assembly Line 1
Walk Way
Assembly Line 2
Walk Way
Final Rectification

10. • Decoiler is a mechanical
component in which the sheet
metal, available in coiled form
which is used for
manufacturing of long
member, is de-coiled.
• Hydraulic Motor is present for
tightening
• The pressure arm is located on
the to maintain the contact of
the coil.
• Some of the initial cut pieces
are dumped because of their
hardness and not straight cut.
• A red indicator is there to
signal the presence of the coil.

11. The machine is suitable for synchronizing with wire feeder or strip feeder. Synchronization
will enable the machine to start unwinding the machine when there is consumption of
material in the process. Otherwise the unwinding activity is stopped.
It is a heavy construction by design to sustain the load of the material in the form of coil.
The construction consist of three wings with adjustable jaws(either mechanized or
manual). The unwinding action takes while the motor and gear box cranks the wings.
Center of gravity is taken care in the design.
The rotation is controlled by a limit switch or a wire with no potential supply to enable or
disable the unwinding action with reference to the consumption of the material.
The equipment and the covers are fully protected from getting corroded by means of zinc
blue /black/green and powder coating.

12. Decoiler is used in press shops and other engineering applications where in the sheets
are wires in the form of coil is being unwound in a mechanized way to feed the same to
the next stage.
• Complete electrical controls.
• Motor, Couplings and Gear box assembly.
• Lubrication Provision.
• Protection guards.
• Manual and motorized adjustment of jaws.
• Limit switch control for synchronizing with feeder or Press.
• Service and maintenance schedule chart.

14. The machine is suitable for synchronizing with strip feeder, power press and pneumatic presses.
It is a heavy construction by design to sustain the stress levels while it remove the bends in the
sheets. The construction consist of the Ground hardened and hard chrome coated bottom set and
top set of rollers. The bottom rollers are mutually linked by gears driven by a main drive motor
through gear box.
There are totally one set of feed rollers which is used for feeding the sheets. Top rollers are
individually adjustable to adjust and improve the straightness. The rollers are adjustable as a set
of gang.
The machine is suitable for synchronizing with strip feeder, power press and pneumatic presses.
It is a heavy construction by design to sustain the stress levels while it remove the bends in the
sheets. The construction consist of the Ground hardened and hard chrome coated bottom set and
top set of rollers. The bottom rollers are mutually linked by gears driven by a main drive motor
through gear box.
There are totally one set of feed rollers which is used for feeding the sheets. Top rollers are
individually adjustable to adjust and improve the straightness. The rollers are adjustable as a set
of gang.
The equipment and the covers are fully protected from getting corroded by means of zinc blue
/black/green and powder coating.

15. Decambering is the metalworking process of removing camber, or horizontal
bend, from strip shaped materials. The material may be finite length sections or
continuous coils. Decambering resembles flattening or levelling processes, but
deforms the material edge (left or right) instead of the face (up or down) of the strip.

17. Basic check valve allows
fluid to flow in one
direction, in this case
from bottom to top.
Shown are ISO symbol
and cross-sectional photo
of spring-loaded check
valve. The spring keeps
fluid from flowing unless
downstream pressure
acting on the poppet
overcomes spring force.
• Refers to the shifting of valves from fully open to fully
closed.
• It causes the flow to rapidly accelerate and decelerate.
• Three types of Valve Positions :
a ) Extend
b ) Retract
c ) Neutral
• Proportional valves on the other hand control direction
and speed, can also control actuator direction, speed,
acceleration and deceleration.
TypesofDirectionalControl
Valve
Discrete ( More than two or three positons
)
Proportional
Digital ( On and Off Positons )

18. • Primary Characteristics for selecting a Directional
Control Valves are :
a ) Number of Fluid Ports.
b ) Number of Directional States of Positions the valve
can achieve.
• Number of Position refers to the number of distinct
flow paths a valve can provide ( 4-Port,3-Position
Spool Valve ).

19. Schematic shows simple circuit to
control cylinder extension and
retraction using a 4-port, 3-position
spool valve.
Arranging digital valves into a hydraulic
integrated circuit allows them to accomplish
the same functions as discrete spool-type
valves while retaining the advantages of digital
valves.

20. • Main Cylinder
• Ram Locking Cylinder
• Ejector
• Die Caterpillar
• Cushion
• Prefill
• Tool Carriage
• Ram Slide
• Damping Cylinder
• Straightner Cassette
• Tool Clamping Cylinder
• Slide Lubrication Tank
• Hydro Motor
• IFS Conveyor Belt
• Magnetic Transverse
• OFS
• Shearing Blade
• RAM
• Cassette
• Measuring Head
• Kohler Pump
• Centering Cylinder
• Tool Turnover Device

22. There are 21 Ejectors connected in the 5000 Ton Press, The primary
objective of the ejector is to eject the long member when the head ram is
moving upwards after notching, forming and piercing process.

24. • A device for shifting the control members of hydraulic actuating mechanism with
simultaneous power amplification of the controlling action.
• A cylinder or fluid motor that converts hydraulic power into useful mechanical work.
• Actuators are used to pivot a joint.
Actuators
Rotatory
Actuators
Helical Spline
Enclosed
Piston Crank
Scotch Yoke
Rack and
Pinion
Piston Chain
Bladder and
Vane Actuator
Single Vane
Double Vane

25. 1 • PREWASH SYSTEM
2 • SHOT BLASTING
3 • DIP DEGRESSING
4 • WATER RINSE
5 • DEIONISED RINSE - I
6 • DEIONISED RINSE - 2

26. 9 • CED
10 • ULTRA FILTRATION-1
11 • ULTRAFILTRATION- 2
12 • RECYCLED DEMINERALISED WATER
13 • BAKING OVEN
14 • LINE
7 • TECTALIS ( 5800 )
8 • DEIONISED RINSE-3

27. Fitment of Front SPG. Hanger BKT. And Reinforcement
Fitment of ENG MTG. and 10 Dia. Riveting
Slide Support Riveting and Gusset Fitment
SPG. HANG BKT. BOLT ( M14 ) Tightening
Hole Alignment and 10 Dia Bolt Tightening
Fitment of Cross Members
10 Dia. Horizontal Riveting END CM Bolt Tightening
Rear SPG. BKT. Bolt Tightening
OPERATINGSTATIONSOF FRAME SHOPLINE 1 & 2

28. Hole Alignment and Rivet Insertions, END CM Bolt Tightening
10 and 12 Dia Horizontal Riveting
Vertical ( 10 and 12 Dia ) Riveting
Frame Inversion
12 Dia Horizontal Riveting and END CM BOLT Tightening
BOLT Tightening 10 and 12 Dia Riveting, Inspection
Final Inspection and Dispatch to Paint Shop
Rectification
Frame Painting
Frame Baking Oven - 1

29. Riveting
Operation
Nut
Runners
Frame and Operations Performed on it

30. Frame Drop
Chasis Number Punching
Link Rod Fitment
Propeller Shaft Fitment
Lift Axle Kit Fitment
Front Leaf Spring Fitment
Rear Leaf Spring Fitment
Steering Gear Box Fitment
OPERATINGSTATIONSOF ASSEMBLY LINE

31. Rear Axle/Lift Axle Drop
Front Axle/Dummy Axle Drop
Rear/Dummy Axle Tightening
Front/Lift Axle Tightening
Quality Gate
Chasis Inversion
Brake/Fuel Pipe Fitment
Front Shock Absorber and Steering Pipe Fitment
Engine Drop
Propeller Shaft Fitment with Gear Box

32. Mounting Processin ASSEMBLY LINE

33. Silencer Muffler Fitment/Quality Gate
Radiation Drop
Fuel Tank BKT. Fitment
Cab/Cowl Drop
Battery BKT. Fitment
Battery Drop and Fuel Tank Fitment
Wheel Fitment
Wheel Nut Tightening
Clutch Oil/Coolant/Diesel Filling
Steering Oil Feeling/Engine Cranking

34. Spare Wheel Fitment/Air Leakage Test
QA Check
Quality Gate
Side Shield Fitment
Smoke Test

35. Side Layout of Assembled Truck ( Ready
for Testing)
Front Layout of Assembled Truck ( Ready
for Testing)

36. THANKYOU