Table of contents

1. i
Candidate’s Declaration
I hereby declare that the work presented in this report entitled“ Industrial training at VE
commercial vehicle” in partial fulfilment of the requirements for the award of Degree of
Bachelor of Technology, submitted in the Department of Mechanical Engineering at Arya
college of engineering and IT, Jaipur, is an authentic record of my own work under the
supervision of ER. Sandeep Bhauskar.
I also declare that the work embodied in the present project report is my original
work/extension of the existing work and has not been copied from any Journal/thesis/book,
and has not been submitted by me for any other Degree/Diploma.
Harsh Koria
Roll No. – 15EARME049

2. ii
ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and deep regards to my guide for his
exemplary guidance, monitoring and constant encouragement throughout the training period.
The blessing, help and guidance given by him time to time shall carry me a long way in the
journey of life on which I am about to embark.
I also take this opportunity to express a deep sense of gratitude to Er. Sanjay Manghnani –
Department of Mechanical Engineering, for his cordial support, valuable information and
guidance, which helped me in completing this task through various stages.
I am obliged to staff members of VE COMERCIAL VEHICLES, for the valuable
information provided by them in their respective fields. I am grateful for their cooperation
during the period of my assignment.
Harsh Koria
B tech 4th year
Mechanical Engineering

3. iii
ABSTRACT
A student gets theoretical knowledge from classroom and gets practical knowledge from
industrial training. When these two aspects of theoretical knowledge and practical experience
together then a student is fully equipped to secure his best.
In conducting the project study in an industry, students get exposed and have knowledge of
real situation in the work field and gains experience from them. The object of the summer
training cum project is to provide an opportunity to experience the practical aspect of
Technology in any organization. It provides a chance to get the feel of the organization and
its function.
I was assigned to the New Product Development section in the supervision of Er. Sandeep
Bhauskar who gave me knowledge about measurement of product by measuring instruments
and gauges. I learnt lots of basic manufacturing processes like milling, hobbing, shaping etc.

4. iv
Contents
Title Page no.
Candidate’s Declaration i
Acknowledgement ii
Abstract iii
Contents iv
List of Figures vii
List of Tables viii
Chapter 1 Introduction 1-7
1.1 Introduction of VECV 1
1.1.1 Key points 1
1.1.2 VECV Overview 3
1.1.3 Market Share 5
1.2 Business area of VECV 6
1.3 Vision and Mission 6
1.3.1 Vision 6
1.3.2 Mission 6
CHAPTER 2 EICHER ENGINEERING COMPONENTS 8-19
2.1 About EEC 8
2.1.1 In house products 8
2.1.2 Outsourced product 8
2.1.3 Gear box assembly 8
2.2 Gear manufacturing 9
2.2.1 Selection of material 9
2.3 Gear manufacturing process 9
2.3.1 Gear forming 9
2.3.2 Form milling 9
2.2.5 Broaching 9
2.4 Gear generation 10
2.5 Casting 10

5. v
2.5.1 Types of casting 11
2.6 Fettling 11
2.7 Casting process simulation 12
2.8 Forging 12
2.8.1 Types of forging 13
2.9 Extrusion 16
2.9.1 Types of Extrusion 16
2.8.1 Types of forging 13
2.8.1 Types of forging 13
CHAPTER 3 NEW PRODUCT DEVELOPMENT 20-35
3.1 Introduction 20
3.2 Processes 20
3.3 Marketing product duration 21
3.4 Feasibility 21
3.5 Tooling cost 21
3.6 Gauge design 22
3.6.1 Types of gauges 22
3.7 Control Plan 26
3.7.1 Why control plan 26
3.7.2 How to develop control plan 27
3.7.3 Level of control plan 27
3.8 Production Part Approval Process 28
3.8.1 Why PPAP 28
3.8.2 When to perform PPAP 28
3.8.3 How to perform PPAP 29
3.8.4 PPAP Level of submission 29
3.8.5 Elements of PPAP 29
3.9 Production 30
3.9.1 Hobbing 30
3.9.2 Gear shaping 34

6. vi
3.9.3 Gear shaving 35
3.9.4 Gear teeth grinding 35
CHAPTER 4 HEAT TREATMENT 36-40
4.1 Introduction 36
4.2 Pre Hardening 37
4.2.1 Annealing 37
4.2.2 Normalizing 37
4.2.3 Stress relief 37
4.3 Heat treating 38
4.3.1 Quenching 38
4.3.2 Quench hardening 38
CHAPTER 5 CONCLUSION 41
REFRENCES 42

7. vii
LIST OF FIGURES
Figure No. Name of Figure Page No.
1.1 Eicher trucks and busses 03
1.2 Volvo Trucks India 03
1.3 Eicher engineering components 04
1.4 VE powertrain 04
1.5 Market share 05
1.6 VECV sales trend 05
2.1 Casting process 10
2.2 Forged part 13
2.3 Drop forging 14
2.4 Extrusion process 16
3.1 Plug gauge 22
3.2 Height gauge 23
3.3 Ring gauge 24
3.4 Functional Gauge 25
3.5 Control Plan 26
3.6 CNC Hobbing machine 31
3.7 Hob Cutter 32
3.8 Hob Nomenclature 33
3.9 Shaping Machine 34

8. viii
LIST OF TABLES
Table No. Name Of Table Page No.
1.1 Business Area of VECV 6
2.1 Hot extrusion temperature for various
metals
17
3.1 Process Chart 20