The document provides details about Atul Malhotra's semester training at Swaraj Engines Limited in Mohali, India. It includes: - An introduction to Swaraj Engines Limited, describing its establishment and production of diesel engines. - An overview of the various departments, including the Assembly Shop where Atul was trained. - Details of Atul's objectives for the training, which were to gain new skills, study processes, and complete projects under supervision. - A description of key tasks Atul carried out, such as analyzing the bumping process to set piston clearance and studying the production line for connecting rods.

1. PRESENTATION
OF
SEMESTER TRAINING, UNDERTAKEN
AT
SWARAJ ENGINES LIMITED
INDUSTRIAL AREA, PHASE 9, MOHALI.
IN
(ASSEMBLY SHOP)
SUBMITTED BY:
ATUL MALHOTRA (CUN110104023)
M.E 8-X
CHITKARA UNIVERSITY
1

2. LIST OF CONTENTS
Brief outline of the company
Brief outline of the department
Objectives of the training
Detailed Objective of the Training
Work Carried out during the training and projects
undertaken
Significant contribution

3. INTRODUCTIN TO SEL
Swaraj Engines Ltd. (SEL) is manufacturing engines for fitment into “Swaraj”
tractors being manufactured by Mahindra & Mahindra Limited (M&M) at its
Swaraj Division. SEL is also supplying hi-tech engine components to SML Isuzu
Ltd., the erstwhile Swaraj Mazda Ltd, for assembly of commercial vehicle
engines.
The company was incorporated on 24th September 1985, and obtained the
Certificate of Business on 16th October, 1985. The company has been promoted
jointly by Punjab Tractors Ltd. and Kirloskar Oil Engines Ltd. Kirloskar Oil
Engines, Ltd. agreed to provide know-how, design and documentation of
products, process details, design of jigs, fixtures and tooling etc. to the company
for the manufacture of diesel engines to be fitted in `SWARAJ' tractors
manufactured by Punjab Tractors Ltd.
The factory is quite competitively modernized with regard to manufacturing
technology. It has the unique distinction of employing the maximum number of
CNC’s north of Delhi. Since start of commercial operations in 1989-90, SEL has
supplied over 5,00,000 engines for fitment into “Swaraj” tractors.

4. VARIOUS DEPARTMENTS OF S.E.L
• INDUSTRIAL ENGINEERING
• MACHINE SHOP
• ASSEMBLY AND TESTING SHOP
• QUALITY SHOP
• MAINTENANCE SHOP
• TOOL ROOM
• STANDARD ROOM AND TOOL CRIB
• STORES

5. ASSEMBLY SHOP
An assembly line is a manufacturing process (most of the time called
a progressive assembly) in which parts (usually interchangeable parts) are
added as the semi-finished assembly moves from work station to work station
where the parts are added in sequence until the final assembly is produced.
By mechanically moving the parts to the assembly work and moving the semi-
finished assembly from work station to work station, a finished product can
be assembled faster and with less labour than by having workers carry parts
to a stationary piece for assembly. Assembly lines are the common method of
assembling complex items such as automobiles and other transportation
equipmentThe engines assembled here includes,
• S-15, Single Cylinder 25 BHP
• RV-2, Two Cylinder 24 BHP
• RV-3, Three Cylinder 39.5 BHP
• RB-30, Three Cylinder 44 BHP
• RB-33, Three Cylinder 55 BHP

6. ASSEMBLY PROCESS FOLLOWED AT SHOP
• CRANK SHAFT FITMENT
• CAM SHAFT FITMENT
• GEAR CASING FITMENT
• CRITICAL AREA PISTON ASSEMBLY
• CYLINDER BLOCK FITMENT
• OIL SUMP FITMENT
• CYLINDER HEAD FITMENT
• WATER PUMP FITMENT
• FIP [FUEL INJECTION PUMP] FITMENT
• FUEL TIMING

7. OBJECTIVES OF THE TRAINING:
• One of the main objective of the training is to gain new skills and look
closely into how industry works ?
• To study about the processes carried out in the department allotted to me.
• To study about the sections, processes and operations done in the
department.
• To complete all the projects done under the supervision of my department
head.

8.  BUMPING: It is a process in which T.D.C. of engine cylinder or
clearance between piston and cylinder head is set by placing shims
between liner and cylinder head.
WORK CARRIED OUT

9. Bumping Clearance:
Clearance volume or bumping clearance is the space between the top of the piston
and the cylinder head of an engine. This clearance is an important aspect of the
engines and should be optimized to improve the efficiency of the engine.
Significance and Effects of Bumping Clearance:
In an engine, when the discharge valve closes in the end of the compression cycle, a
small amount of high pressure air is trapped in the clearance volume. Before again
taking suction, the air trapped in the clearance volume must expand below the
suction pressure i.e. below the atmospheric pressure. The expansion of this trapped
air in the clearance volume causes effective loss of stroke due to which the
volumetric efficiency of engine drops. Therefore, the clearance volume has a
significant effect on the efficiency of the engine.

10. STEPS INVOLVED IN BUMPING:
Marking T.D.C:
When the first piston from flywheel side is at its T.D.C. then a point is
marked below the pointer fitted on the gear casing.

11. Placing Shim:
Shims are the spacer of big size which are inserted between liners and
cylinder head in order to lift the cylinder head to avoid head noise.

12. How Bumping Clearance is checked?
Bumping clearance is checked by putting a plastic gauge over the piston and
then turning the engine one revolution by hand. By doing this the lead ball
will compress and the thickness obtained is the clearance volume. This
thickness is measured with micrometre and is then compared with the
manufacturer’s value. Adjustments are made in case there is an offset in the
value.
Adjustment of bumping clearance:
Bumping clearance can be adjusted with the help of inserting shims(thin
metallic plates). Inserting shims will move the connecting rod and the piston
which will change the clearance.

13. Bumping gauge and bumping tool:

14. Bumping shim and CV shim:
The shim which is bigger in size and placed at outer surface of liner is
known as bumping shim. This shim is used to support the cylinder
head. The shim which is smaller in size as compared to bumping shim
and placed at inner surface of liner is known as CV shim. This shim is
used to provide clearance between piston and cylinder head.

15. What should be the Bumping Clearance?
Generally bumping clearance depends on the manufacturer but as a thumb
rule it should be between 0.5% to 1% of the bore of the cylinder.
Shims used of various thickness according to various reading:
Reading thickness of shim for,
positive reading 1.2mm
0 to -0.10 1.2mm
-0.10 to-0.20 1.2mm
-0.20 to-0.30 1.3mm
-0.30 to-0.40 1.4mm
-0.40 to-0.5 0 1.5mm
These are the readings for Bombay engine.

16. RESEARCH AND ANALYSIS: Under this we were asked to observe all the
processes carried out in the assembly shop carefully and then prepare report
on Stage 1 and Stage 2 of the assembly shop.

17.  STUDY THE AVL CONNECTING ROD LINE:
Incoming from Vendor No. Punching
( Marks Pryor)
Bolt Hole
(BFW)
Rough Boring and Semi Finish
(WIDMA)
Boring and Fine Finish
(WIDMA)
Parameter Checking
Marposs)
De-burring Weight Grouping
Assembly Shop
Bush PressingOil Hole Drilling
In Small End
Chamfering Of
Large End
Cap and Con Rod
Assembly (
Torquing)

18. Group Weight In Kg.
A 1.630 1.650
B 1.651 1.670
C 1.671 1.690
D 1.691 1.710
E 1.711 1.730
F 1.731 1.750
G 1.751 1.770
H 1.771 1.790
I 1.791 1.810
J 1.811 1.830
WEIGHT GROUPING OF AVL CONNECTING ROD:

19. SIGNIFICANT CONTRIBUTION:
1. One of my significant contributions has been the documentation of the
jobs that have been assigned to me to the department supervisor.
2. Submitting the reports on the stage 1 and stage 2 of the assembly shop.
3. Analyzing the bumping process and preparing report on that.
4. Preparing the flow chart of the AVL connecting rod line in the
industry.

20. THANK YOU