SUMMER TRAINING PROJECT REPORT

ESCORTS INDIA PVT. LTD. AGRI

MACHINERY GROUP, FARIDABAD

METHODS INVOLVED IN THE PROCESS OF

PRODUCTION OF REAR AXLE

Prepared By :

ROHIT KUMAR
Roll No. - 1314340084
B-tech - Mechanical
IMS ENGINEERING COLLEGE

PREFACE

Industrial exposure is the most crucial part of the

technical studies in which a student is able to
synchronize his technical knowledge with practical
knowledge gained in any of the organization in which he
gets his training from. I was allotted a project titled,
Methods involved in the process of Production of REAR
AXLE, in ESCORTS INDIA PVT LTD, FARMTRAC DIVISION.
I hope that the word of my project communicates the
actual experience gained with subtlety and precision,
which is unapproachable, by any other means. From the
medium of this project report, I would like to thank each
and every honorable employee of ESCORTS INDIA PVT
LTD FARMTRAC DIVISION, who has helped me to gain all
the knowledge in the respective production shop, where
production process was involved.

INDEX

Company Profile
The Founding Philosophy
Background
Overview Manufacturing
Overview Material Management
Methods Involed
Design
Final Inspection

COMPANY PROFILE

ABOUT THE COMPANY

The

Escorts

Group

is

among

India's

leading

engineering

conglomerates operating in the high growth sectors of agri-machinery,

construction & material handling equipment, railway equipment and auto
components.

Having pioneered farm mechanization in the country, Escorts has played

a pivotal role in the agricultural growth of India for over five decades. One
of the leading tractor manufacturers of the country, Escorts offers a
comprehensive range of tractors, more than 45 variants starting from 25
to 80 HP. Escort, Farmtrac and Powertrac are the widely accepted and
preferred brands of tractors from the house of Escorts.
A leading material handling and construction equipment manufacturer,
we manufacture and market a diverse range of equipment like cranes,
loaders, vibratory rollers and forklifts. Escorts today is the world's largest
Pick

'n'

Carry

Hydraulic

Mobile

Crane

manufacturer.

Escorts has been a major player in the railway equipment business in

India for nearly five decades. Our product offering includes brakes,
couplers, shock absorbers, rail fastening systems,composite brake blocks
and vulcanized rubber parts.
In the auto components segment, Escorts is a leading manufacturer of
auto suspension products including shock absorbers and telescopic front

forks. Over the years, with continuous development and improvement in

manufacturing technology and design, new reliable products have been
introduced.
Throughout the evolution of Escorts, technology has always been its
greatest ally for growth. In the over six decades of our inception, Escorts
has been much more than just being one of India's largest engineering
companies. It has been a harbinger of new technology, a prime mover on
the industrial front, at every stage introducing products and technologies
that helped take the country forward in key growth areas. Over a
million tractors and over 16,000 construction and material handling
equipment that

have

rolled

out

from

the

facilities

of

Escorts,

complemented by a highly satisfied customer base, are testimony to the

manufacturing excellence of Escorts. Following the globally accepted best
manufacturing

practices

with

relentless

focus

on

research

and

development, Escorts is today in the league of premier corporate entities

in

India.

Technological and business collaboration with world leaders over the

years, Globally competitive indigenous engineering capabilities, over
1600 sales and service outlets and footprints in over 40 countries have
been instrumental in making Escorts the Indian multinational. At a time
when the world is looking at India as an outsourcing destination, Escorts
is rightly placed to be the dependable outsourcing partner of world's
leading engineering corporations looking at outsourcing manufacture of
engines, transmissions, gears, hydraulics, implements and attachments
to

tractors,

and

shock

absorbers

for

heavy

trailers.

In today's Global Market Place, Escorts is fast on the path of an internal

transformation, which will help it to be a key driver of manufacturing
excellence in the global arena. For this we are going beyond just adhering

to prevailing norms, we are setting our own standards and relentlessly

pursuing them to achieve our desired benchmarks of excellence.

THE FOUNDING PHILOSOPHY

Over six decades back two young men set out on a journey together
armed with little beyond intelligence, business acumen and determination
and dreams aplenty. They believed that India could only achieve total
freedom with a breakthrough in the field of agriculture and mechanization
would have to rule the fields. Their youthful enthusiasm had kindled the
hope that one day they would make a mark of their own. They were in
fact writing the first chapter of what has come to be widely recognized as
one of the greatest success stories in Indian industry.
Escorts came into being with a vision. A vision that eschewed easy paths
to profitability, and sought instead for ways to make a contribution. A
vision that led two young brothers, Yudi and Hari Nanda, to branch out of
their family's prospering transport business and institute ventures that
were to become the foundations of Escorts Limited. On 17th October
1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with
Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. It
was a trendsetting marketing house driven by the same business
philosophy, which had given their family enterprise an unrivalled
reputation: customer concern. Not long afterwards, this driving ambition
to go beyond the expected led Hari Nanda to the first of his many
successful business insights - the discovery of the great business
potential that lay in India's villages. This led to the launch, in 1948, of

Escorts (Agriculture and Machines) Ltd., with Yudi Nanda as Director.

Though separate business entities then, both companies had two great
strengths in common: the dynamic Nanda brothers and the unifying force
of the name they gave their companies; Escorts, literally 'escorting' their
products and services to the customer while most other businessmen
were just selling.
Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit
remained embedded in the foundations of the company. Mr. H P Nanda
then took on the mantle to realize the dreams which he had always seen
with his brother.
Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged
in 1953 to create a single entity -Escorts Agents Pvt Ltd. Having initially
started with a franchise for Westinghouse domestic appliances, by this
time the Company had already expanded its marketing and service
operations, representing internationally known German and American
organizations such as MAN, AEG, Haniel & Leug, Knorr Bremse, MIAG and
BMA for sophisticated electrical and mechanical engineering equipment
and

Minneapolis

Moline

and

Wisconsin

for

agricultural

tractors,

implements and engines. Escorts made a major thrust into the

agricultural arena by taking on the marketing and service franchise for
Massey Ferguson tractors in Northern India, which soon comprised 75% of
MF's all-India sales - a signal tribute to Escorts' inherent strengths. Its first
industrial venture came up in 1954, in partnership with Goetzewerke of
Germany for the manufacture of piston rings and cylinder liners - followed
by production of pistons in collaboration with MAHLE, also of Germany, in
1960. The company's incorporation in its present name, Escorts Limited,
was effected on 18th January, 1960. Escorts' next major industrial activity
was the assembly of tractors in 1961 in technical cooperation with URSUS
of Poland. Subsequently this led to the manufacture of the country's first
indigenous tractors under Escorts' own brand name, which were to play a
pivotal role in the Green Revolution. This went on to lay the foundations

that even today are the Company's core strengths -relevant, worldstandard

technology

through

strategic

international

alliances;

broadbased marketing and service network yet unrivalled.

Beyond the growth of the organization, these principles have ensured that
Mr. H. P. Nanda's contribution to the cause of industry and the consumer
will endure. He pioneered the revolutionary concept of 'interdependence'
between

ancillary

and

large

industries,

institutionalizing

vendor

development and in the process building Faridabad and the entire belt of
townships in the region. He introduced the discipline of service going
before marketing, reassuring the customer that Escorts would stay with
them, that they were here for the long run. He built lasting alliances with
an array of the world's most respected names in tractors, industrial
equipment,

two-wheelers,

construction

equipment

and

telecommunications. Going further, he created institutions devoted to

value engineering and training, not only as investments in the company's
future but also as catalysts for the enhancement of Indian industry as a
whole the Escorts R&D Centre and the unique Escorts Institute of Farm
Mechanization. His concern extended to the society in which he worked,
and he manifested it by establishing the Escorts Medical Centre at
Faridabad, Escorts Heart Institute and Research Centre at New Delhi, as
well as numerous village development programmes. And above all, he
imbued the corporation with his own pioneering.

Escorts is testimony to the valor, vision and values of its Founder Mr. H P
Nanda. He remains the inspiration for our courage, spirit of adventure and
ability to Think Big. These qualities are his enduring legacy and have
inspired and encouraged us down the decades and will continue doing so
in all our endeavors.

Background
In 1960, our parent company, Escorts, set up the strategic Agri
Machinery Group (AMG) to venture into tractors.
In 1965, we rolled out our first batch of tractors under the brand name of
Escort.
In 1969 a separate company, Escorts Tractors Ltd., was established with
equity participation of Ford Motor Co., Basildon, UK for the manufacture
of Ford agricultural tractors in India.

In the year 1996 Escorts Tractors Ltd. formally merged with the parent
company, Escorts Ltd.
Since inception, we have manufactured over 1 million tractors.

Overview Manufacturing
Escorts - AMG has Tractor manufacturing capacity of 98,940 trs / annum
which is the highest in Asia at one location. Its manufacturing operations
are divided in three plants as
Component Plant
Tractor Assembly Plant
Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings

such as Engine blocks, Gear Box housings, Differential housings are being
machined along with Gears & Shafts. Machine shop consists of State of
the Art machines such as CNC Horizontal Machining Centers, CNC Turning
Centers and variety of other precision machines, including Gear Hobbing
and Shaving machines, etc. It is important to note that all critical
components are machined in house.
Tractor Assembly Plant is divided into two lines as Farmtrac Line and the
Powertrac Line. Farmtrac Line is a composite line that has machining as
well as assembly activities of Engine, Transmission & Tractor whereas on
Powertrac line only Assembly activities of Engine, Transnmission& Tractor
are being carried out. Tractor Assembly Plant has State of the Art Paint
Shop that has CED paint shop facilities. Engine Shop has State of the Art
testing facilities that includes AVL make Eddy Current Dynamometers in
Engine Test House.
Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line
and Hydraulics Line. Crankshaft line consists of machine shop where
crankshafts of all Tractor models are being machined. It has State of the
Art machines such as Rotary Miller, Pin Grinder, Journal Grinder, etc.
Hydraulic line consists of Machining as well as Assembly activities where
critical parts of tractor hydraulics such as Distributor, Hydraulic Cylinder,
etc are being machined and assembled. It has State of the Art Honing and
other precision machines.

Overview Materials Management

Presently procuring materials for 72,000 tractors per annum.

Present procurement value over US$ 30 million.

Production will rise to 100,000 tractors per annum in 2 years.
Procurement value will rise to almost US$ 45 million in that period.
Presently 387 suppliers of which over 95% are India domestic.
Advantages of low costs of materials in India.
Items procured are:
Castings
Forgings
Machined Parts
Proprietaries
Sheet Metal
Hardware

METHODS
INVOLVED IN THE
PROCESS OF
PRODUCTION OF
REAR AXLE

DESIGN OF THE REAR AXLE SHAFT

REAR AXLE PRODUCTION UNIT

S. No

OPERATION

MACHINE

OPERATION

CYCLE

DESCRIPTIO
N
FINISH
TURNING OF
BIG END
FLANGE

EQUIPMEN
T
NCL-15;
NCL-16
KWS MAKE
CNC LATHE

2.

DRILL AND
FINISH HOLE
MILL 8 NOS
BOLT HOLES
THROUGH
AND DRILL 2
NOS
MANUFACTU
RING HOLES

HMD-19
BATLIBOL
MAKE
MULTIDRIL
LING
MACHINE

3.

FORM OIL
GROOVE ON
STEM END
FACE
CHAMFERIN
G OF BACK
FACE OF 8
NOS BOLT
HOLES
MILLING OF
38 INVOLUTE
SPLINES ON
STEM END

ETL-01

4.

5.

VLM-03

SMM-02
HURTH
MAKE
SPLINE
MILLING

1. DRUM DIA
2. BIG END
FLANGE DIA
3. LENGTH OF
DRUM DIA
4. FLANGE
WIDTH
5. LENGTH OF
SEAL DIA
6. LENGTH OF
BEARING DIA
7. THREAD SIZE
8. THREAD
LENGTH
9. LENGTH OF
SPLINES
10.
LENGTH
OF SEAL DIA
11.
STEM
DIA
12.
FILLET
RADIUS OF
STEM TAPER
DIA
13.
SURFACE
FINISHING OF
STEM TAPER
DIA
1. BOLT HOLE
DIA
2. BOLT HOLE
COORDINATES
3. MANUFACTURI
NG HOLE DIA
4. MANUFACTURI
NG HOLE COORDINATES
1. OIL GROOVE
DEPTH
2. OIL GROOVE
PROFILE
1. CHAMFER DIA
2. CHAMFER
ANGLE
1. NO OF
SPLINES DIA
OVER
MEASURING
PINS.

TIME(MINUT
ES)
8.99(57 JPS)

4.25(124
JPS)

3.43(140
JPS)
3.43(140
JPS)

3.55(104
JPS)

MACHINE
6.

WASHING OF
COMPONENT

WSM-01
THERMAS
MAKE
WASHING
MACHINE

7
.

INDUCTION
HARDENING
OF SHAFT
STEM

IHM-03
IHM-04

8
.

CHECK FILE
HARDNESS
AT NECK &
STEM

2. PCD RUNOUT
3. LENGTH OF
SPLINES
1. EFFECTIVE
CASE DEPTH
ON STEM
2. EFFECTIVE
CASE DEPTH
TOWARDS
FLANGE DIA
3. EFFECTIVE
CASE DEPTH
AT REST DIA
OF SPLINES
4. EFFECTIVE
CASE DEPTH
AT ROOT OF
M-642
THREADS
5. HEAT RUNOUT
ON SPLINED
END
1. QUENCHING
MEDIA
2. TEMP OF
QUENCHING
MEDIA
3. PRESSURE OF
QUENCHING
MEDIA
4. RADIAL GAP
B/W
INDUCTOR &
COMPONENT
5. FACE GAP B/W
INDUCTOR
AND
COMPONENT
6. QUECH LAG
TIME
7. PRE HEATING
TIME
8. POWER
REQUIRED
9. SPINDLE
SPEED
10.
INDUCT
OR
TRANSVERSE
RATE

5(80 JPS)

9
.

1
0
.

NORMALISE
THE SHAFT
IF REQUIRED
FOR
REWORK
FLANGE
HARDENED
STEM AND
FACE

1
1
.

TEMPER THE
INDUCTION
HARDENED
SHAFT

1
2
.

STRAIGHTEN
ING OF
SHAFT STEM

1
3
.

GRINDING
OF SEAL DIA
& FINISH
GRINDING
OF BEARING
DIA &
BEARING
SEATING
FACE

1
4
.

FINISH
GRINDING
OF SEAL DIA

1
5
.

FINISH
GRIND STEM
AND FACE

1
6
.

SUPER
FINISH OF
SEAL DIA

1
6
.

CHECK
CRACK ON
REAR AXLE
SHAFT

IHM-04
INDUCTION
HARDENIN
G MACHINE
FLANGE
HARDENIN
G
EQUIPMEN
T
TFF-04
TFF-05
TEMPERIN
G
FURNACE
HDP-05
BEMCO
MAKE
HYDRAULIC
PRESS
AGR-07
ANGULAR
HEAD
GRINDER

ANGULAR
HEAD
GRINDER
AGR-05
MTC-01
FACE
GRINDING
EQUIPMEN
TS

SFM-02
SUFFINA
MAKE
SUPER
FINISHING
MACHINE
MAGNA
FLUX
CRACK
DETECTOR

SURFACE HARDNESS

TEMP OF
TEMPERING
TEMPERING
PERIOD

RUNOUT ON 47
INVOLUTE SPLINE
DIA
1. SEAL DIA
2. BEARING DIA
3. SURFACE
FINISH ON
BEARING DIA
4. DIST OF
BEARING
SEATINGFACE
FROM FLANGE
FRONT
LENGTH OF SEAL
DIA
SURFACE FINISH OF
SEAL DIA
1. SURFACE
FINISH OF
STEM END
FACE
2. LENGTH OF
STEM END
FACE wrt
BEARING
STEATING
FACE
1. SEAL DIA
SURFACE
FINISH OF
SEAL DIA
1. FREE FROM
CRACKS

3.45(139JPS
)

2.91(165
JPS)
4.21(132
JPS)

2(132 JPS)

1
7
.

FINAL
INSPECTION
OF SHAFT
REAR AXLE

STAGE

2. AS PER
PART PRINT
SPECIFICATI
ON

2(132 JPS)

OPERATIONS PERFORMED
FINISH TURN SHAFT REAR AXLE AND CUT
THREADS

MACHINE TYPE - NCL-15;NCL-16

CUTTING PARAMETERS:TOOL NO
06
07
0101
04

FEED
0.016/0.20
0.006/0.12
0.0787/RN
0.012/RN

SPEED
750ft/mtr
750ft/mtr
650ft/mtr
700ft/mtr

GAUGE USED
1.
2.
3.
4.
5.
6.
7.
8.

G-30327
G-85004/2
G-30405
G-85004/1
G-30329
G-30327
G-30345
G-30343

TESTING SHAFT RUNOUT CHECKING

AFTER CNC

OPERATERS PROCEDURE(BENCH CENTRE)

1. MOUNT THE COMPONENT ON CENTRE

2.
3.
4.
5.

SHAFT SHOULD BE ALLIGN WITH CENTRE

CHECK THE SHAFT FOR ROTATION ON THE CENTRES.
MOUNT THE DIAL GAUGE ON THE TABLE & CHECK THE RUNOUT.
CHECK THE RUNOUT & IF CHANGE IN DIMENSION, THEN CHECK THE
FEED ON THE MACHINE.

TO DRILL AND REAM 8 BOLT HOLES

ON FLANGE

DRILL TWO

MANUFACTURING HOLES.
OPERATION
POSITION OF 8 HOLES
AFTER DRILLING
POSITION OF 8 HOLES
AFTER MILLING
DIA 740/.760
DIA .6675/.6595(HOLE
MILL)

GAUGES
4235 AAEG 27

CHECKING FREQUENCY
1 SHIFT

4235 AAEG 4

1 SHIFT

G-40088
g-40087

1/50
1/10

DRILLS USED - 4235AA-ET-85A

HOLE MILLS - 4235AA ET 86A
4235AA EG 27
7235 AA EG 4

LIMIT GAUGES - G-40088

G-40087

OIL GROOVE ON STEM END FACE

CUTTER USED - FM CUTTER 4235 AET 5

CUTTING SPEED - 800 RPM
FEED BY HAND
GAUGE TO CHECK 4235 AEG 6

CHAMFER ON 8 HOLES

CHAMFER SIZE - .070+ 0.10X45

CHECKING FREQUENCY - 1/160
TOOL USED - TS COUNTERSUNK CUTTER DIA 3/4X90

FINISH MILL 38 & 47 INVOLUTE

SPLINES

TOOL & M/C SETTINGS CUTTER - 4235A ET 83(FOR 47 SPLINE)

REEMER - 4235A-ET 9(FOR 38 SPLINES)
FACE CENTRE - 4235AA EF 44/1
TAIL STOCK CENTRE - MA-321/25
GAUGES USED 4235 EG 71
4235 AEG 29
4235 AEG 28
4235 AEG 72
SPEED - 180 RPM
FEED - 400M/MIN

SHAFT INDUCTION HARDENING

QUENCH PRESSURE = 5-7.5 Kg/cu.cm
QUENCH TEMPERATURE = 25C-45C
GAP = 0.085/.110

TEMPER INDUCTION HARDENING OF

SHAFT

FURNACE TEMPERATURE - 230C-240C

TIME PERIOD - 1.5-2.5 HRS
CHARACTERISTICS CHANGE OF BASE COLOUR TO GOLDEN COLOUR.

GRIND SEAL DIAMETER

GRINDING WHEEL - 4235 AET 87

CENTRE - MT-5(2 NOS)
DRESSING DIAMOND - MA 902/37

 FINISH GRIND SEAL DIAMETER

TAPER CUT GRINDING WHEEL :- 100/68X40X31.75

SUPER FINISH SEAL DIA :- 2.105/2
STONE USED :- 60mmX60mmX18mm
OSCILATOR DRIVE PRESSURE :- 1.5 2.5 BAR.

 STAGE INSPECTION
CHECK LIST:1. 8 NOS BOLT HOLE DIA OF 0.6675/0.6595
2. SEAL DIA OF 2.100/2.105
3. SEAL DIA OF 2.6265/2.6275
4. LENGTH OF 29.096/29.042
5. 38 SPLINE FOR ALLIGNMENT
6. 47 SPLINE FOR ALLIGNMENT
7. IF ABOVE COMPONENT IS TIGHT THEN IT IS SENT FOR REWORK.

CRACK CHECKING(MAGNA FLUX)

CURRENT RATING :- 2200-2800 AMPS

IF BLUE LIGHT SHOWS THEN PIECE IS REJECTED OTHERWISE
PASSED WITH OK SIGN.

Bibliography
www.google.com

 www.wikipedia.com
www.escortagri.com
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