Ashok leyland motors
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AUTOMOBILES SKIN PANEL INSPECTION & METAL FINISHING PROJECT REPORT ON
ASHOK LEYLANDAshok Leyland is the 2nd biggest automobile manufacturers in India. Founded in 1948 as ASHOK MOTORS by Mr.RAGHUNANDAN SARAN, an Industrialist. At present there are 6 plants in India, & also serving in 30 countries around the world.Mother plant at ENNORE in chennai, in HOSUR two plants(Unit 1 & Unit 2),ALWAR in Rajasthan, BHANDARA in Maharashtra & recently new plant at PANTANAGAR.
ASHOK LEYLAND PRODUCES LCV : Light Commercial Vehicles MDV : Medium Duty Vehicles HDV : Heavy Duty Vehicles ICV : Intermediate Commercial Vehicles Recently ASHOK LEYLAND has stepped in production of Luxury car. Buses from 18 to 80 seaters are manufactured. Trucks ranging from 4.5 tones to 49 tones .
Second Largest Automobile Vehicle Manufacturer in INDIAASHOKLEYLAND and IVECO joint venture in 1993 1994
In 1954, GOVERNMENT approval for manufacture of commercial vehiclesThe name of the company was changed to ASHOK LEYLAND LIMITED in 1955
Our Defence Vehicle is backbone of INDIAN ARMY
Ashok Leyland Passenger TransportationAshok Leyland buses carry more than 60 million passengers everyday, More comparing to Indian Railways.Ashok Leyland is the India's only manufacturer of doubledecker buses.
It head started in alternate energy buses BS II & BS III. Eight out of ten metro state transport buses in India are from Ashok Leyland.
It is one of the leading suppliers of defense vehicles in the world and also the leading supplier of logistics vehicles to the Indian Army.
What is SKIN PANEL ?SKIN PANEL is a visual outer body of a vehicle majorly CABIN parts Proper metal finished skin panels are very important for good ASTHETIC LOOK of a vehicle.
This report Skin Panel Inspection report is regarding the ASHOK LEYLANDs model named DOST.
DOST model is in joint venture with NISSAN MOTORS.
DOST is awarded as LCV of the year 2012.
Continues..Basically DOST model has 14 SKIN PANELS.Each panel is identified by a Part No.All panels are stamped(pressed) in ASHOK LEYLAND press shop.Sheet metal thickness ranges from 0.7mm to 1.6mm.
The 14 skin panels of DOST areDoor outer RH Door outer LH Door inner RH Door inner LH Roof Floor Front Panel Sill outer RH Sill outer LH Corner Panel RHCorner Panel LHBack PanelB Pillar RHB Pillar LH
Assembled CABIN of DOST
Front panel of DOST
Left hand door of DOST
Inspection of Skin PanelsVisual inspection is popular way of inspecting skin panels. Manually inspecting by wearing inspection GlovesCMM is used in some critical areasOil stoning the panel with Oil stone. Major Defects On Skin Panel DENTS : Dent refers to shallow deformation on the surface of a panel or object. Reason : 1. Due to some dust & foreign particles on die surface. 2. Rarely during loading and unloading of panel.2. PEAKS : Peak refers to a high point on the surface of a panel or object.
Reason :Dust & foreign particles on die surface.During loading & unloading of panel.
DENTS MARKPEAKS MARK
3.WRINKLE : Wrinkle refers to waviness formed on surface of panel. Wrinkle can also be known as high and low areas. Reason : 1. Low cushion pressure. 2. Varying Cylinder forces. 4.WELDING DAMAGE : Welding damage means spot damage. which may damage the channel, flange. Reason :Due to mislocation.Urgency.Due to Child part defect.Weld burning, blackening.Due to high current value.5. CRACKS :Crack is a thin & narrow opening in a flat, solid material. Before crack THINNING occurs.Reason : Due to more holding, blanking pressure.Slug mark.
Tools used for inspectionThe most important tool for inspection is OIL STONE.Hand Gloves.Taper Scale.Pin point micrometer.Vernier Caliper. CMM(Coordinate Measuring Machine).Flash light.
METAL FINISHING:-Metal finishing(Rework) is a process which includes rework of SKIN PANEL DEFECTS, cleaning of panels, providing proper finish & preparing the panel for next painting stage.METAL FINISHING OPERATIONSIn this primarily panels will be cleaned from oil, sealant & rust.Rework of defects will be done in this stage.For peaks, they will hammer it slowly and will finish with VERTICAL SANDER then finally with RANDOM ORBITAL SANDER.For dents they will use a special equipment called DENT PULLER.For cracks the solution is welding , grinding & matching the surface. We use MIG(Metal Inert Gas)welding for cracked surface & also for thinning.To remove welded spot in case of weld damage we will use a SPOT REMOVAEBLE DRILL & after correction it will be welded again.