tata-proj

Submitted by- SWAPNIL SRIVASTAVA

1

PROJECT REPORT ON

PRODUCTION ENGINEERING

DEPARTMENT

TATA MOTORS LTD, LUCKNOW

SUBMITTED BY:-

SWAPNIL SRIVASTAVA

B.Tech (ME) 2012-2016

Raj Kumar Goel Institute of Technology (UPTU), Ghaziabad

UNDER THE GUIDENCE OF:

Mr. MAYUR GANDHI

(-TCF Logistics Centre)

TATA MOTORS LTD. LUCKNOW


2

DECLARATION

This is to certify that this project report on “Production Engineering

Department” is the bona-fide work of Swapnil Srivastava student of

B.Tech Mechanical Engineering Department, Raj Kumar Goel

Institute of Technology (UPTU) Ghaziabad who carried out his project

under my supervision in Tata Motors Lucknow.

His performance was commendable throughout the training period. The

project assigned to him was completed within the specific period, i.e.

from 23rd June 2015 to 23rd July 2015.

We wish him success in the future and believe that this training will help

him in his goals ahead.

This is to be certified that the above statement made by the student is correct to

the best of our knowledge and belief.

Mr. Irfan Habib

-Manager SCM

TATA MOTORS LTD.LUCKNOW

Mr. Mayur Gandhi Mr. Prashant Pandey

-Manager Logistics Centre Talent Acquisition - HR

TATA MOTORS LTD. LUCKNOW TATA MOTORS LTD. LUCKNOW


3

ACKNOWLEDGEMENT

I would like to pay my gratitude to all those who guided and have been with me

throughout my training tenure without whom I could not have completed this

project.

I am very thankful to my project guide Mr. Mayur Gandhi for guiding throughout

this duration and Mr. Irfan Habib for sharing his knowledge with me. Also a

special thanks toMr. Vibhu Satyamfrom TATA Prolife for being coordinative to

all aspects of my tenure at TATA MOTORS.

I would also thank all the operators working in the TATA plant and my training

colleagues with whom I developed a special bond.

Also my sincere thanks to Mr. Prashant Pandey and all the staff members of

TATA MOTORS for providing me the oppurtunity to add a new dimension in my

knowledge by being trained in this esteemed organization.

SWAPNIL SRIVASTAVA


4

ABSTRACT

The title of my project is “Production Engineering Department”. This is

basically a case study on the PE Department of TATA motors which is an

important part of any industry. Not only in TATA Motors but in any industry either

manufacturing or assemby all for the seamless working require the PE

Department which createsall the fixures and templates for any department or

even any other plant. Production engineering is a combination of manufacturing

technology with management science. A production engineer typically has a wide

knowledge of engineering practices and is aware of the management challenges

related to production. The goal is to accomplish the production process in the

smoothest, most-judicious and most-economic way.

In industry, once the design is realized, production engineering concepts

regarding work-study, ergonomics, operation research, manufacturing

management, materials management, production planning, etc., play important

roles in efficient production processes. These deal with integrated design and

efficient planning of the entire manufacturing system, which is becoming

increasingly complex with the emergence of sophisticated production methods

and control systems.

This department is not only needed but in actual without this the functioning of

any plant would become a lot difficult. This is very necessary and useful.

https://en.wikipedia.org/wiki/Manufacturing

https://en.wikipedia.org/wiki/Management_science

https://en.wikipedia.org/wiki/Engineering

https://en.wikipedia.org/wiki/Industry

https://en.wikipedia.org/wiki/Ergonomics

https://en.wikipedia.org/wiki/Operation_research

https://en.wikipedia.org/wiki/Materials_management

https://en.wikipedia.org/wiki/Production_planning

https://en.wikipedia.org/wiki/Integrated_design


5

Industry Profile – TATA Motors

Brief Profile

TATA MOTORS LTD.

Type Public

Industry Automotive

Founded 1945 by J. R. D. Tata

Headquarters Mumbai, Maharashtra, India

Area served Worldwide

Key people

Cyrus Pallonji Mistry (Chairman)

Ravi Kant (Vice Chairman)

Karl Slym (Managing Director)

Revenue US$ 32.67 billion (2012)

Employees 59,759 (2012)

Subsidiaries Jaguar Land Rover, Tata Daewoo, Tata Hispano

Website www.tatamotors.com

History TATA Motors Limited is India's largest automobile company, with consolidated revenues of

₹1,65,654 crores ($32.5 billion) in 2011-12. It is the leader in commercial vehicles in each

segment, and among the top in passenger vehicles with winning products in the compact,

midsize car and utility vehicle segments. It is also the world's fourth largest truck and bus

manufacturer. The TATA Motors Group's over 55,000 employees are guided by the mission "to

be passionate in anticipating and providing the best vehicles and experiences that excite our

customers globally." Established in 1945, TATA Motors' presence cuts across the length and

breadth of India. Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in

1954. The company's manufacturing base in India is spread across Jamshedpur (Jharkhand),

Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and

Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial

joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat


6

and Tata cars and Fiat powertrains. The company's dealership, sales, services and spare parts

network comprises over 3,500 touch points.

TATA Motors, also listed in the New York Stock Exchange (September 2004), has emerged as

an international automobile company. Through subsidiaries and associate companies, TATA

Motors has operations in the UK, South Korea, Thailand, Spain, South Africa and Indonesia.

Among them is Jaguar Land Rover, acquired in 2008. In 2004, it acquired the Daewoo

Commercial Vehicles Company, South Korea's second largest truck maker. The rechristened

Tata Daewoo Commercial Vehicles Company has launched several new products in the Korean

market, while also exporting these products to several international markets. Today two-thirds of

heavy commercial vehicle exports out of South Korea are from Tata Daewoo. In 2005, TATA

Motors acquired a 21% stake in Hispano Carrocera, a reputed Spanish bus and coach

manufacturer, and subsequently the remaining stake in 2009. Hispano's presence is being

expanded in other markets. In 2006, TATA Motors formed a 51:49 joint venture with the Brazil-

based, Marco polo, a global leader in body-building for buses and coaches to manufacture fully-

built buses and coaches for India - their plants are located in Dharwad and Lucknow. In 2006,

TATA Motors entered into joint venture with Thonburi Automotive Assembly Plant Company of

Thailand to manufacture and market the company's pickup vehicles in Thailand, and entered

the market in 2008. TATA Motors (SA) (Proprietary) Ltd., TATA Motors' joint venture with Tata

Africa Holding (Pty) Ltd. set up in 2011, has an assembly plant in Rosslyn, north of Pretoria.

The plant can assemble semi knocked down (SKD) kits, light, medium and heavy commercial

vehicles ranging from 4 tonnes to 50 tonnes.

TATA Motors is also expanding its international footprint, established through exports since

1961. The company's commercial and passenger vehicles are already being marketed in

several countries in Europe, Africa, the Middle East, South East Asia, South Asia, South

America, CIS and Russia. It has franchisee/joint venture assembly operations in Bangladesh,

Ukraine, and Senegal. The foundation of the company's growth over the last 66 years is a deep

understanding of economic stimuli and customer needs, and the ability to translate them into

customer-desired offerings through leading edge R&D. With over 4,500 engineers, scientists

and technicians the company's Engineering Research Centre, established in 1966, has enabled

pioneering technologies and products. The company today has R&D centres in Pune,

Jamshedpur, Lucknow, Dharwad in India, and in South Korea, Spain, and the UK.


7

It was TATA Motors, which launched the first indigenously developed Light Commercial Vehicle

in 1986. In 2005, TATA Motors created a new segment by launching the Tata Ace, India's first

indigenously developed mini-truck. In 2009, the company launched its globally benchmarked

Prima range of trucks and in 2012 the Ultra range of international standard light commercial

vehicles. In their power, speed, carrying capacity, operating economy and trims, they will

introduce new benchmarks in India and match the best in the world in performance at a lower

life-cycle cost.

TATA Motors also introduced India's first Sports Utility Vehicle in 1991 and, in 1998, the Tata

Indica, India's first fully indigenous passenger car.

In January 2008, TATA Motors unveiled its People's Car, the Tata Nano. The Tata Nano has

been subsequently launched, as planned, in India in March 2009, and subsequently in 2011 in

Nepal and Sri Lanka. A development, which signifies a first for the global automobile industry,

the Nano brings the joy of a car within the reach of thousands of families.

The TATA Motors Culture

TATA Motors is equally focussed on environment-friendly technologies in emissions and

alternative fuels. It has developed electric and hybrid vehicles both for personal and public

transportation. It has also been implementing several environment-friendly technologies in

manufacturing processes, significantly enhancing resource conservation.

Through its subsidiaries, the company is engaged in engineering and automotive solutions,

automotive vehicle components manufacturing and supply chain activities, vehicle financing,

and machine tools and factory automation solutions.

TATA Motors is committed to improving the quality of life of communities by working on four

thrust areas - employability, education, health and environment. The activities touch the lives of

more than a million citizens. The company's support on education and employability is focused

on youth and women. They range from schools to technical education institutes to actual

facilitation of income generation. In health, the company's intervention is in both preventive and

curative health care. The goal of environment protection is achieved through tree plantation,

conserving water and creating new water bodies and, last but not the least, by introducing

appropriate technologies in vehicles and operations for constantly enhancing environment care.

With the foundation of its rich heritage, TATA Motors today is etching a refulgent future.


8

Subsidiaries and Joint-Ventures

Tata Daewoo In 2004, TATA Motors acquired Daewoo

Commercial Vehicle Company of South Korea.

The reasons behind the acquisition were:

1. Company's global plans to reduce domestic

exposure. The domestic commercial vehicle

market is highly cyclical in nature and prone

to fluctuations in the domestic economy. TATA Motors has a high domestic exposure of

~94% in the MHCV segment and ~84% in the light commercial vehicle (LCV) segment.

Since the domestic commercial vehicle sales of the company are at the mercy of the

structural economic factors, it is increasingly looking at the international markets. The

company plans to diversify into various markets across the world in both MHCV as well as

LCV segments.

2. To expand the product portfolio TATA Motors recently introduced the 25MT GVW Tata

Novus from Daewoo‟s (South Korea) (TDCV) platform. Tata plans to leverage on the strong

presence of TDCV in the heavy-tonnage range and introduce products in India at an

appropriate time. This was mainly to cater to the international market and also to cater to

the domestic market where a major improvement in the Road infrastructure was done

through the National Highway Development Project.

Tata Daewoo is the second-largest heavy commercial vehicle manufacturer in South Korea.

TATA Motors has jointly worked with Tata Daewoo to develop trucks such as Novus and World

Truck and buses including Globus and StarBus

Tata Hispano Tata Hispano Motors Carrocera, S.A. is a bus and coach cabin manufacturer based in

Zaragoza, Aragon, Spain and a wholly owned

subsidiary of TATA Motors. Tata Hispano has

plants in Zaragoza, Spain and Casablanca,

Morocco. TATA Motors first acquired a 21% stake

in Hispano Carrocera SA in 2005, and acquired the

remaining 79% for an undisclosed sum in 2009,

making it a fully owned subsidiary, subsequently

renamed Tata Hispano.


9

Jaguar Land Rover Jaguar Land Rover PLC is a British premium automaker headquartered in Whitley, Coventry,

United Kingdom and has been a wholly owned subsidiary of TATA Motors since June 2008,

when it was acquired from Ford

Motor Company. Its principal activity

is the development, manufacture

and sale of Jaguar luxury and sports

cars and Land Rover premium four

wheel drive vehicles. It also owns

the currently

dormant Daimler, Lanchester and Rover brands.

Jaguar Land Rover has two design centres and three assembly plants in the UK. Under Tata

ownership, Jaguar Land Rover has launched new vehicles including the Range Rover Evoque,

Jaguar F-Type and the fourth-generation Range Rover.

Tata Marcopolo Tata Marcopolo is a bus manufacturing joint

venture between TATA Motors (51%) and

the Brazil-based Marcopolo S.A. (49%). The

joint venture manufactures and assembles

fully built buses and coaches targeted at

developing mass rapid transportation

systems. It utilises technology and expertise

in chassis and aggregates from TATA

Motors, and know-how in processes and

systems for bodybuilding and bus body design

from Marcopolo. Tata Marcopolo has launched a low-floor city bus which is widely used by

Chennai, Coimbatore, Delhi, Hyderabad, Mumbai, Lucknow, Pune, Kochi, Trivandrum and

Bengaluru transport corporations. Its manufacturing facility is based in Dharwad and Lucknow.

Fiat India Automobiles TATA Motors also formed a joint venture with Fiat and gained access to Fiat‟s diesel

engine technology. TATA Motors sells Fiat cars in India through a 50/50 joint venture Fiat

Automobiles India Limited, and is looking to extend its relationship with Fiat and Iveco to other

segments.


10

Business overview

TATA Motors has diversified in to a range of activities all related to the automobile industry.

Through its subsidiaries, the company is involved in engineering and automotive products,

construction equipment manufacturing, automotive vehicle components manufacturing and

supply chain activities, machine tools and factory automation products, high-precision tooling,

electronic components for automotive and computer applications, and automotive retailing and

service operations. The company's manufacturing base is spread across India. In the east they

are based in Jamshedpur (Jharkhand). Pune (Maharashtra) is their main centre for the west. In

the north, they are present in Lucknow (Uttar Pradesh) and Pantnagar (Uttarakhand). A new

plant to manufacture Nano which was being constructed in West Bengal has been moved

Sanand in Gujarat.

TATA Motors focuses on Research and Development and has over 2,500 engineers and

scientists working for the company‟s Engineering Research Centre. The company has R&D

centres in Pune, Jamshedpur, Lucknow, in India, and in South Korea, Spain, and the UK. It has

developed the first commercially viable prototype of air power car. On 25th July 2008, it also

announced to launch the electric version of Nano in Europe by Dec 2009. The company‟s

dealership, sales, services and spare parts network comprises over 3500 touch points; TTM

also distributes and markets Fiat branded cars in India.

TATA Motors operates in four main automobile segments which cover the range of products in

the automobile segments in India.

Passenger Cars: This segment accounts

for 30.5% of the total production volume

During FY2008, 182,292 units of gasoline and

diesel engine versions were manufactured and

sold. This division also distributes Fiat branded

cars in India. TATA Motors has a presence in

the compact car, mid-sized car and station

wagon segment of the market in the form of

Indica, Indigo and Indigo Marina and their variants. In FY2008, the passenger car industry grew

by 11.9% in India, but the TATA Motors sales in this segment declined by 7.3% due to no new

product launches. The market share of TATA Motors in this segment declined from 15.6% to

13.3%. All the passenger cars are manufactured at plants at Pimpri and Chinchwad district in

Maharashtra. TATA Motors has launched "Nano", an affordable family car with a price tag of

₹1,10,000 for the developing world. The project was delayed as the public opposition and

political problems forced the management to abandon the plant site at Singur, West Bengal and

shift it to Sanand, Gujarat.


11

Utility Vehicles: TATA Motors entered the utility vehicle with the launch of Tata Sumo in

1994. Later it also entered SUV segment with the launch of Tata Safari in 1998. This segment

accounts for 8.4% of the total production volume. The sales in this segment were 47,530 units,

a decline 0.8% as compared to 47,892 units in FY2007. The overall market share in this

category is 20.1%. TATA Motors lost 2% of the market share due to lack of any new, product or

a variant of the existing product in this segment. All the utility vehicles are manufactured at

plants in Pimpri and Chinchwad district in Maharashtra.

Light Commercial Vehicles: TATA Motors manufactures light commercial vehicles

including pickup trucks, trucks and buses with gross vehicle weight of between 0.7 ton and 7.5

tons. This segment grew by 17.2% growth to 147,316 units sold in the Indian domestic market

in FY2008 and constituted 29.1% of the total

units sold. TATA Motors entered this

category by indigenously developing a low

priced product Ace (mini-truck) with a 0.7 ton

payload in fiscal 2006. In FY2008, TATA

Motors launched two other products, Magic a

passenger variant of Ace and Winger. It also

announced to introduce CNG variant of the

Ace, the Tata Cargo Panel Van, a lifestyle

pickup truck (Xenon XT) and an office concept vehicle at the Auto Expo 2008 in India. TATA

Motors has a market share of 64.2% in this segment. The light commercial vehicles are

manufactured at Pantnagar plant in Uttarakhand.

Medium and Heavy Commercial Vehicles: TATA Motors manufactures medium

and heavy commercial vehicles which include trucks, buses, dumpers and multi-axle vehicles

with GVW of between 9 tons to 49 tons. In addition, through Tata Daewoo Commercial Vehicle

Company Limited, or TDCV, a wholly-owned subsidiary in South Korea, TATA Motors

manufactures high horsepower trucks ranging from 220 horsepower to 400 horsepower,

including dump trucks, tractor-trailers, mixers and cargo vehicles. This segment constituted 32%

of the total volumes in FY2008. During the same period it declined by 4.2% to 165,619 units as

compared to FY2007. The decline was due to the lack of availability of vehicle finance from

outside sources and constraints in the components and aggregates supply chain. TTM has a

market share of 64.17% in this segment. In India, TATA Motors manufactures the Medium and

Heavy Commercial Vehicles in manufacturing plants at Jamshedpur, Jharkhand and Lucknow,

Uttar Pradesh.


12

Global Challenges

TATA Motors has some distinct advantages in comparison to other multi-national competitors.

There is definite cost advantage as labour cost is 8-9% of sales as against 30-35% of sales in

developed economies. TATA Motors has extensive backward and forward linkages and it is

strongly interwoven with machine tools and metals sectors. Tata Group's strong expertise in the

IT based engineering solution for products and process integration has helped TATA Motors.

India has one of the world's largest auto component industry noted for its world class

capabilities. There is huge demand in domestic markets due to infrastructure developments and

TATA Motors is able to leverage its knowledge of Indian market. There are favourable

Government policies and regulations to boost the auto industry.

However, major multi-national automakers are moving their operations to India to cut costs.

Volvo, a manufacturer of trucks, buses, cars, construction equipment, and aero engines, had

entered in India in 1998. Its main focus is in the area of fully built buses. In India, it has focused

on providing economical transport solutions in consonance with its values of safety, quality, and

environmental care. Its competitive advantage is its high technology which makes the vehicle a

very comfortable option to travel through. Its trucks are reputed for their performance and

economy and are the flag bearers in their production activities in India. It is still operating in the

niche market of high end buses where the Tata compete through its Hispano Carrocera and

Marcopolo buses.

The Government of India last announced an automobile policy in December 1997. The policy

required majority-owned subsidiaries of foreign car firms to invest at least US$50 million in

equity if they wished to set up manufacturing projects in India. It also forced them to take on

export obligations to fund their auto part imports and required them to submit to a schedule for

increasing the share of locally made parts in their cars. Mere car assembling operations were

not welcomed.

An Indian cabinet panel will soon consider a new automobile policy that aims to set fresh

investment guidelines for foreign firms wishing to manufacture vehicles in the country.

Investments in making auto parts by a foreign vehicle maker will also be considered a part of

the minimum foreign investment made by it in an auto-making subsidiary in India. The move is

aimed at helping India emerge as a hub for global manufacturing and sourcing for auto parts.

The policy sets an export target of $1 billion by 2005 and US$2.7 billion by 2010. The policies

adopted by Government will increase competition in domestic market, motivate many foreign

commercial vehicle manufactures to set up shops in India, whom will make India as a

production hub and export to nearest market. Thus TATA Motors Commercial Vehicles will have

to face tough competition in near future, which might affect its growth negatively.


13

Competition in Heavy Vehicles

Mahindra and Mahindra: M&M has formed a 51:49 joint venture called Mahindra

International with ITEC, USA (parent Navistar International), to manufacture commercial

vehicles and to bolster its position in the business. ITEC is the leader in medium and heavy

trucks and buses in North America, and is the world's largest manufacturer of medium-duty

diesel engines. Mahindra International aims to have a presence across the commercial vehicles

market (6-35 tonnes GVW) with variants of passenger transport, cargo and specialised load

applications and is likely to start producing medium/heavy commercial vehicles from FY09.

Force Motors: Force Motors has paired up with MAN in a 70:30 joint venture to

manufacture high-tonnage and specialty vehicles, such as long-haul trucks, tippers, tractor

trailers and multi-axle vehicles in the 16-32 tonne range at its Pithampur plant, with an initial

capacity of 24,000 units per annum and at an investment of ₹7 billion. The joint venture plans to

sell nearly half of its production in the domestic market, while the rest is to be exported to the

Middle East, Turkey, Russia, Asia and Africa. Further, the two companies have formed another

JV to manufacture buses in India from end-2007.

Ashok Leyland: Ashok Leyland recently acquired the truck unit of Czech Republic-based

Avia for US$35m. Avia manufactures 6-9 tonne LCVs and has a capacity of 20,000 units per

annum. The acquisition has given ALL direct access to an entire range of Avia trucks, Avia‟s

press shop with dies and tools, welding lines, state-of-the-art paint shop and R&D facilities.

Ashok Leyland has also entered into technology agreements with Hino Motors of Japan and ZF

of Germany to complement its in-house R&D efforts and developing complementary

components and aggregates.


14

Competition in Passenger Cars

Maruti Suzuki India: Maruti Suzuki India Limited is a subsidiary of Suzuki Motor

Corporation. It was formerly known as Maruti Udyog Limited. The Group's principal activity is to

manufacture, purchase and sale of Motor Vehicles and Spare parts. The Group is a subsidiary

of Suzuki Motor Corporation. The other activities of the Group comprises of dealership network

of Pre-Owned Car Sales, Fleet Management and Car Financing. The Group also provides

services like framing of customized car policies, economical leasing of cars, maintenance

management, registration and insurance management, emergency assistance and accident

management. The product range includes ten basic models with more than 50 variants. The

Group has operations in over 1220 cities with more than 2628 outlets and also exports cars to

other countries. It also exports its products to Asia, Africa, and South and Latin America.

Hyundai Motor Company: Based in Seoul, South Korea, Hyundai Motor Company

manufactures and distributes motor vehicles and parts worldwide. It offers passenger cars,

recreational vehicles and commercial vehicles, including light commercial vehicles; medium and

heavy duty trucks; special vehicles, such as refrigerated van truck, dry van truck, wing body

truck, and trailer wing body/bottle carriers; medium and large size buses; and bare chassis.

Honda: Headquartered in Tokyo, Honda Motor Co., Ltd., together with its subsidiaries

develops, manufactures and distributes motorcycles, automobiles, and power products

worldwide. Its motorcycle business manufactures motorcycles, all-terrain vehicles, and personal

watercrafts. Honda‟s motorcycle line consists of sports, business, and commuter models. Its

automobile business offers passenger cars, multiwagons, minivans, sport utility vehicles and

mini cars. The company also offers various financial services to its customers and dealers. In

addition, it manufactures various power products, including power tillers, portable generators,

general-purpose engines, grass cutters, outboard engines, water pumps, snow throwers, power

carriers, power sprayers, lawn mowers, and lawn tractors. Honda sells its products through

various outlets, wholesalers, and independent retail dealers.

Toyota: Headquartered in Toyota City, Japan, Toyota Motor Corporation operates in the

automotive industry worldwide. It designs, manufactures, assembles, and distributes passenger

cars, recreational and sport-utility vehicles, minivans and trucks, and related parts and

accessories. It also offers hybrid vehicles. Its products also comprise conventional engine

vehicles, including subcompact and compact cars, mini-vehicles, passenger vehicles,

commercial vehicles, auto parts, mid-size models and luxury models. In addition, Toyota offers

sports and specialty vehicles, recreational and sport-utility vehicles, pickup trucks, minivans and

cab wagons, trucks and buses. Further, the company provides finance to dealers and their

customers for the purchase or lease of Toyota vehicles.

http://www.wikinvest.com/wiki/Maruti_Suzuki_India

http://www.wikinvest.com/wiki/Hyundai_Motor_Company

http://www.wikinvest.com/wiki/Honda

http://www.wikinvest.com/wiki/Toyota


15

TATA Motors Vehicle range

Conventional Full forward Semi forward

Conventional Control Chassis:

All controls (Accelerator, clutch & brake) are behind the engine.

Less noise and vibrations in cabin.

More safety to the driver.

Visibility is poor.

Full Forward Control Chassis:

All controls mounted in front of engine.

Better visibility.

Getting more loading area.

Safety of the driver is less.

Semi forward Control Chassis:

All controls mounted by the side of engine.

More safe for driver and passenger.


16

Light commercial vehicles

Tata 207 DI single cab:497 SP, diesel and direct injection engine, vacuum-assisted

hydraulic dual-circuit breaks with tandem master cylinder.

Tata 207 DI crew cab:497 SP, diesel, direct-injection engine with vacuum-assisted

hydraulic dual-circuit breaks with tandem master cylinder.

SFC 407 Ex turbo truck:497 SP turbo (India 2000) engine, vacuum-assisted hydraulic

dual-circuit breaks with tandem master cylinder.

SFC 407 turbo truck:497 SP turbo engine with vacuum-assisted hydraulic dual-circuit

breaks with tandem master cylinder; available in cab load-body, cab chassis, truck cowl

and bus cowl versions.

Intermediate commercial vehicles

LPT 1109 turbo truck: 497 turbo four-cylinder engine with dual-circuit full air S-Cam

brakes.

LP 1109 turbo truck: 497 turbo four-cylinder engine with dual-circuit full air S-Cam

brakes.

Medium and heavy commercial vehicles

LPT 1615 TC turbo heavy-duty truck: Cummins 6 BT

5.9 TC water-cooled, turbo-charged diesel engine with

6 inline cylinders, dual-circuit full air S-CAM service

brakes.

SE 1613 TC turbo truck:Cummins 6 BT 5.9 TC water-

cooled, turbo-charged diesel engine. With 6 inline

cylinders and dual-circuit full air S-CAM service brakes.

LPT 1613 TC turbo truck: Cummins 6 BT 5.9 TC water-cooled, turbo-charged diesel

engine with 6 inline cylinders and dual-circuit full air S-CAM service brakes.


17

LPT 2515 TC turbo truck: Cummins 6 BT 5.9 TC water-cooled, turbo-charged inter

cooled diesel engine with 6 inline cylinders and dual-circuit full air S-CAM service

brakes.

LPT 2516 TC: With Cummins 6 BT AA 5.9 TC water-cooled, turbo-charged, inter-cooled

diesel engine with 6 inline cylinders and dual-circuit full air S-CAM service brakes.

Buses

SFC 407 turbo mini- bus: 497 SP turbo water-cooled direct injection diesel engine with

vacuum-assisted dual circuit hydraulic with tandem master cylinder.

LPO 1510 CGS bus (CNG bus): 6B 5.9 CNG NA engine with 6 inline cylinders, fully

duplicated full air S-CAM brake system.

LP / LPO 1510 Bharat stage II bus: 697 NA engine with 6 inline cylinders, fully

duplicated full air S-CAM brake system.

LPO 1616 TC inter luxury Bharat stage II bus:With Cummins 6 BT AA 5.9 TC water-

cooled, turbo-charged, inter-cooled diesel engine and 6 inline cylinders and dual-circuit

full air S-CAM service brakes.


18

Defense vehicles

Tata 407 (4x4) soft-top troop carrier: 4 SP turbo engines with vacuum-assisted

independent hydraulic brakes.

Tata 407 / (4x2) hard-top troop carrier: 4 SP TC engine with vacuum-assisted

hydraulic dual circuit breaks and tandem master cylinder (exhaust brake optional).

Tata SD 1015 TC (4x4): Cummins 6 BT engine with air over hydraulic breaks with

independent hydraulic circuit for front and rear.

Tata LPTA 1621 TC (6x6): Cummins 6 BT engine with dual circuit full air S-CAM brakes

and provision for trailer brakes.

PLANT LOCATION


19

TATA Motors - Lucknow Plant

Overview

TATA Motors Lucknow is one of the youngest production facilities among all the TATA Motors locations

and was established in 1992 to meet the demand for Commercial Vehicles in the Indian market. The

state-of-the-art plant is strongly backed by an Engineering Research Centre and Service set-up to

support with latest technology and cater to the complexities of automobile manufacturing. Fully Built

Vehicle business, which is one of the fast growing areas of business, is also established in Lucknow.

The plant rolls out commercial vehicles and is specialised in the designing and manufacturing of a range

of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses.

TATA Motors Lucknow is a third manufacturing unit of Tata Engineering and Locomotive Company. This

unit covers an area of 600 acres. In this unit the assembly of chassis and spare parts takes place. On 14th

January 1992 the recruitment of operators started in Lucknow plant. On 25th June induction of Engineers

(first phase) started which also included ITI's and Occupancy of administration office of assembly shop in

September 1992. First vehicle rolled out from Lucknow plant on 20th October 1992 which was LP 1210

52. Construction of MRS finished on 6th January 1993. It took approximately 9 years since the

conception of the plan and to rollout the first vehicle from this latest manufacturing facility of TATA

Motors. Plant Head Mr. Rajnish Julka, currently heads this Unit.

The Lucknow facility also specializes in manufacturing HCBS (High capacity Bus System) buses. In light of

Company’s aggressive growth plans, the plant is currently in expansion phase and production at

Lucknow would grow manifold in near future.


20

Currently, the following manufacturing and assembly units exist within the plant:

Assembly Line 1

ERC Proto Shop

PE and Transmission shop

Integral Bus Factory (IBF)

Assembly Line The assembly lines in TATA Motors, Lucknow are slat conveyors with roller chains whose speed can be

varied between 0.1 to 2.2 m/min. The length of slat conveyor for MCV line is 76.2 mts. and can

accommodate a maximum of 24 vehicles. The Length of slat conveyor for LCV Line is 68.85 mts. and can

also accommodate a maximum of 24 vehicles.

The HCV/MCV/LCV assembly line is semi-automated and is divided into 3 sections:

Frame Shop

Trim/Cowl Line

Main Assembly Line

Frame Shop

Long members from Jamshedpur plant are supplied by means of trailers and unloaded in the Frame

Shop. Then the long members are transferred to punching area by roller conveyor. In the punching area,

holes are punched by punching guns, using metal templates. Then long members are transferred to

preparation area by using roller conveyor. In the preparation area, reinforcements and spring brackets

are screwed or riveted, as required.

Then both LH and RH long members are

transferred to the Heft fixture using special

tackle, where they are assembled along with

the cross members. Pneumatic clamping force

is used to hold the assembly while tightening.

After clamping, further operations like

screwing and riveting are carried out. Then the

frame is transferred to a conveyor which has

six stations for further bolting and riveting.

Then the frame is inspected and corrected if any discrepancy is found, then transferred to the pre-

cleaning area where it is ground to remove any burr or sharp edges using Pneumatic Sander.

Assembly Line 2

Assembly Line 3

Paint Shop

Body-In-White (Welding Shop)


21

Then the frame is transferred to the paint booth where it is painted with Denitrol, followed by the

baking oven. The frame is baked for 15 min at 120oC. After baking, it is transferred to the prepared

frame storage area. From here, frames are fed to the main chassis assembly line.

Trim/Cowl Line

Cowl is the front portion of the chassis which has driver seat, engine hood, steering wheel, head lights,

instrument cluster, indicators, Retarder ECU, accelerator, brake and clutch pedals and other electrical

connections. Bare cowls are received from Paint Shop in pallets. Their assembly is done here.

The Cowl Cx is divided into two areas:

Bare Cowl Rectification area: The cowls that are received have to be rectified before dropping them on

to the assembly lines. The following processes are done here:

Cowl line: The cowl line is in the form of an endless conveyor on

which fixtures called pilots are attached. The fixtures are of such a

type that they can accommodate all kinds of cowls and FES. The line

starts with the dropping of the cowl on the conveyor. Fitment of all

parts is then carried out on the structure. The line ends with the

inspection, testing and unloading of the cowl on the last station.

Main Assembly Line

The main assembly line consists of 19 stations, from frame dropping

to engine starting. Aggregates like front axle, rear axle, engine etc. are inwarded from Jamshedpur or

Pune; while the rest of the components are supplied by vendors. Some parts are supplied as it is,

whereas others have to sub assembled before fitment on the respective chassis. There is an aggregate

area along the chassis line where sub assembly of parts is done.


22

Productivity Service Department

Productivity: The rate at which a company produces goods or services in relation to the

amount of materials and number of employees needed. This is usually expressed in ratios of

inputs to outputs. That is (input) cost per (output) good/service. For calculation purpose,

expression of productivity is-

Productivity = Output/ Input

Output may be classified as: Input may be defined as:

Parts & product Money

Services Material

Brand/Image/Identity Machine

Satisfaction Man Hours

Victory/ success Methods

Wastage of any type Land

Pollutants of any type, etc

Roles and Responsibility of PSD:-

1. Measures and monitoring of productivity.

2. Work system design, assessment and resource requirement.

3. Custodianship for overall nos. For all types of personnel in the establishment (permanent,

temporary, trainees, job trainees, apprentices)

4. Measures and monitor productivity of plant, cascading of targets and facilitate achievements

of targets.

5. Based on strategy and organization structure define organizational process, systems, work

flow for attaining of plant‟s objectives.

6. Based on the above, defined work content and role of each position.

7. Study area wise resource requirement in line with productivity targets and work assessment.


23

Eastern complex

Tata Motors Ltd. Lucknow has total plant area of 600 acres of which 280 acres are covered in the

western part called Western Block which has a present production capacity of 120 vehicles per day and

now they have planned to increase its daily production capacity to 520 vehicles by extension which is

already going in the form of eastern complex on the other side of ‘Dewa’ road covering the remaining

320 acres. The production capacity of this new assembly plant will expected to be 320 vehicles per day.

The eastern complex would have longest conveyor line of India i.e. 375meters.This eastern complex will

have two conveyers formed by the combination of single chain conveyor and double chain slat

conveyor. These conveyors are named as ‘Line-2’ and ‘Line-3’ (Line-1 is the name given to the conveyor

at western complex). There is also a provision of a future expansion in form of ‘Line-4’ and ‘Line-5’ and

two more trim lines to cater their cowl/cab needs.Line-2’ and‘Line-3’ will be composed of 30 stations of

12.5 meters each in comparison to the 19 stations in the existing line. The complete assembling activity

for the vehicle chassis will be done in these 30 stations. The assembly of cowl/cab will be catered by the

two trim lines, which will be composed of 34 and 40stations respectively. Apart from this, it would also

have the biggest paint shop, which will be dedicated for the painting of cowls and cabs along with the

BIW (Body in White) shop. Presently the cowls are being received from the Jamshedpur which carries a

lot of extra transportation charges will now be seized with the start of Eastern Complex. Moreover in

the Eastern Complex there are many other changes made for the efficient working on the line. Firstly

the line will accommodate the assembling of chassis of various types of MCV`s and HCV`s up to the

upcoming model WORLD TRUCK of TATA. All the equipments and tools etc. will operate over-head so as

to make the more floor surface available and reducing hindrance on the shop floor. Platforms for

accommodating different types of over-head equipments and machines are hanged to the top with

various beams and hangers. Also the aggregates which are the heavy parts required during the chassis

assembly (Engine, Axles, and Cab etc.) will now be moved from storage to the fitment station through

EMS (Electric Monorail System) which will freeze the movement of fork-lifters on the shop floor.

Moreover the docking stations are built aside the wall to dock the material from outside in front of the

station in which that part will go to the assembly line directly. Above all the main thing is that the flow

of work is made in efficient & systematic way to enhance the productivity with the increased safety.


24

Different models of CV assembled in Lucknow plant are:

1.207 DI-MOBILE

2. SFC 407 (Semi Forward Control) CLB/COWL

3. SFC 407 F/L (27 & 31 WB)

4. SFC 709

5. LP 709 (Laden Passenger)

6. LPT 709 (Laden Passenger Truck)

7. LP/LPT 407

8. LP 407(TT)(Twin Tires)

9. LP 407 CNG

10. LPO1512 TC (Laden Passenger Overhung- Tata Cummins Engg.)

11. LPT 1613 TC

12. LPT 1613 CMVR (CMVR Engines)

13. LPO 1520 CNG

14. LPT 2515 TC Ex

15. LPT 3118 TC BS II

16. RE 1615 SLF (Semi Lower Floor)

17. LPO 1510 CNG

18. LP 1510 TC/CMVR

19. LPO 1510CMVR

20. SE 1613 CMVR

21. LPO 1616(EURO 1, EURO 2 & PNEU. SUSP.)

22. LPO 1651 ULF (HCBS)

23. LPO 1623 ULF (HCBS)


25

What Is Production Engineering?

Production engineering develops processes for turning raw materials into a finished

item. Read on to learn more about this field and the responsibilities associated with it.

Schools offering Industrial Engineering degrees can also be found in these popular

choices. Production engineering is a combination of manufacturing technology with

management science. A production engineer typically has a wide knowledge of

engineering practices and is aware of the management challenges related to

production. The goal is to accomplish the production process in the smoothest, most-

judicious and most-economic way. Production engineering encompasses the application

of castings,machining processing, joining processes, metal cutting & tool design,

metrology, machine tools, machining systems, automation, jigs and fixtures, and die and

mould design and material science and design of automobile parts and machine

designing and manufacturing. Production engineering also overlaps substantially with

manufacturing engineering and industrial engineering.

In industry, once the design is realized, production engineering concepts regarding

work-study, ergonomics, operation research, manufacturing management, materials

management, production planning, etc., play important roles in efficient production

processes. These deal with integrated design and efficient planning of the entire

manufacturing system, which is becoming increasingly complex with the emergence of

sophisticated production methods and control systems.

OVERVIEW

Production engineering refers to the intricate design and careful planning that goes into

creating a product. Such a process can be quite broad, incorporating everything from

the initial use of raw materials to the final products made available to consumers as

large-scale durable goods.

http://learn.org/articles/What_is_Production_Engineering.html#searchSummaryAndResults



https://en.wikipedia.org/wiki/Manufacturing

https://en.wikipedia.org/wiki/Management_science

https://en.wikipedia.org/wiki/Engineering

https://en.wikipedia.org/wiki/Casting_%28metalworking%29

https://en.wikipedia.org/wiki/Joiner

https://en.wikipedia.org/wiki/Metrology

https://en.wikipedia.org/wiki/Machining

https://en.wikipedia.org/wiki/Automation

https://en.wikipedia.org/wiki/Manufacturing_engineering

https://en.wikipedia.org/wiki/Industrial_engineering

https://en.wikipedia.org/wiki/Industry

https://en.wikipedia.org/wiki/Ergonomics

https://en.wikipedia.org/wiki/Operation_research



https://en.wikipedia.org/wiki/Production_planning

https://en.wikipedia.org/wiki/Integrated_design


26

Production Engineering Division (PE)- TATA

Production Engineering Division (PE), a captive division of Tata Motors, started operations in 1965. Located at Tata Motors' Pune plant, by far this is the largest tool room in India spread across 30,000 m2 area with a modern and highly-equipped set up along with experienced engineers and specialists to manufacture sheet metal and foundry tools at all levels of complexity. PE's commercial operations started in 2001-2002 and since then have done tooling works for several OEM and Tier 1 companies in India and Europe. With knowledge of vehicle level fitments and engineering in tool making, which is an added benefit to its customers, PE division is aiming to reduce project risks and efficiently manage timelines. PE plays a very important role in BIW tooling of Tata Motors Limited through its New Product Development process. PE's product portfolio comprises Stamping Dies (Press Tools), Sheet-Metal Fixtures, Inspection Fixtures and Gauges, Foundry Tooling and Thermoforming Moulds.


27

Vision, Mission & Core Values


28

Z&B SURFACE GRINDER- CNC 84 Horizontal Surface Grinder

Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used

abrasive machining process in which a spinning wheel covered in rough particles

(grinding wheel) cuts chips of metallic or non-metallic substance from a workpiece,

making a face of it flat or smooth. Surface grinding is the most common of the grinding

operations. It is a finishing process that uses a rotating abrasive wheel to smooth the

flat surface of metallic or non-metallic materials to give them a more refined look or to

attain a desired surface for a functional purpose. The surface grinder is composed of an

abrasive wheel, a work holding device known as a chuck, and a reciprocating or rotary

table. The chuck holds the material in place while it is being worked on. It can do this

one of two ways: ferromagnetic pieces are held in place by a magnetic chuck, while

non-ferromagnetic and non-metallic pieces are held in place by vacuum or mechanical

means. A machine vise (made from ferromagnetic steel or cast iron) placed on the

magnetic chuck can be used to hold non-ferromagnetic work pieces if only a magnetic

chuck is available.


29

Factors to consider in surface grinding are the material of the grinding wheel and the

material of the piece being worked on. Typical workpiece materials include cast iron

and mild steel. These two materials don't tend to clog the grinding wheel while being

processed. Other materials are aluminium, stainless steel, brass and some plastics.

When grinding at high temperatures, the material tends to become weakened and is

more inclined to corrode. This can also result in a loss of magnetism in materials where

this is applicable. The grinding wheel is not limited to a cylindrical shape and can have

a myriad of options that are useful in transferring different geometries to the object

being worked on. Straight wheels can be dressed by the operator to produce custom

geometries. When surface grinding an object, one must keep in mind that the shape of

the wheel will be transferred to the material of the object like a reverse image. Spark

out is a term used when precision values are sought and literally means "until the

sparks are out (no more)". It involves passing the workpiece under the wheel, without

resetting the depth of cut, more than once and generally multiple times. This ensures

that any inconsistencies in the machine or workpiece are eliminated.

DESCRIPTION

Maximum grinding length 800 mm

Maximum grinding width 400 mm

Electromagnetic table 600 x 400 mm

Control CNC Siemens Simatic Op 26


30

TECHNICAL SPECIFICATIONS

Based on the proven design principles of the Grinder series A this machine offers a large variety of functions due to the NC-Superplus-D control and covers many more applications

Grinding area 500 x 250 mm or 800 x 400 mm

Spindle drive 7.5/11/13/22 kW

Distance table to spindle centreline:

600 bmm to 700 mm

Above all the STARLINE series E guarantees for productivity, simple operation philosophy, high righty of the entire systems and provides excellent value for money

This machine features a half enclosure with sliding door

The NC-Superplus-D control widens the machining applications as compared to

the Grinder series A as follows a „variety of different dressing programs with

compensation, possibilities for calibration (straight side dressing),backing-off

(angled side dressing) including wheel management, a wide selection of software

modules are available upon request

Lubricants are sometimes used to cool the workpiece and wheel, lubricate the interface, and

remove scrap(chips). It must be applied directly to the cutting area to ensure that the fluid is not

carried away by the grinding wheel. Common lubricants include water-soluble chemical fluids,

water soluble oils, synthetic oils, and petroleum-based oils. The type of lubrication used

depends on the workpiece material and is outlined in the table below.

Types of lubricants used for grinding based on workpiece material

Workpiece material Lubricant

Aluminium Heavy duty oil

Brass Light duty oil

Cast iron Heavy duty emulsifiable oil, light duty chemical and synthetic oil

Mild steel Heavy duty water-soluble oil

Stainless steel Heavy duty emulsifiable oil, heavy duty chemical and synthetic oil

Plastics Water-soluble oil, dry, heavy duty emulsifiable oil, light duty chemical and synthetic oil


31

MAGNETIC-BED

The job is fixed using a fixture over a magnetic bed which makes it impossible to move

or even vibrates, and is important as while grinding the surface the job might attain high

momentum and could be destructive so is fixed rightly.

CONTROL


32

BFW CONVENTIONAL MILLING- Knee Type Milling Machine

Milling is the most common form of machining, a material removal process, which can

create a variety of features on a part by cutting away the unwanted material. The milling

process requires a milling machine, workpiece, fixture, and cutter. The workpiece is a

piece of pre-shaped material that is secured to the fixture, which itself is attached to a

platform inside the milling

machine. The cutter is a

cutting tool with sharp

teeth that is also secured

in the milling machine and

rotates at high speeds. By

feeding the workpiece

into the rotating cutter,

material is cut away from

this workpiece in the form

of small chips to create

the desired shape. Milling

is typically used to

produce parts that are not

axially symmetric and

have many features, such

as holes, slots, pockets,

and even three

dimensional surface

contours. Parts that are

fabricated completely

through milling often include components that are used in limited quantities, perhaps for

prototypes, such as custom designed fasteners or brackets. Another application of

milling is the fabrication of tooling for other processes. For example, three-dimensional

molds are typically milled. Milling is also commonly used as a secondary process to add

or refine features on parts that were manufactured using a different process. Due to the

high tolerances and surface finishes that milling can offer, it is ideal for adding precision

features to a part whose basic shape has already been formed.


33

RIGID STRUCTUREThe rigid structure enables smooth, vibration-free machining. The

rigid spindle housing, cross ribbed box type column structure, and the closed box-type

knee design facilitate optimum chip removal and surface finish.

WORK SPINDLE- Optimum spacing of precision taper roller bearings enables vibration-

free cutting. The bearing pre-loading is adjusted through a common nut.

COOLANT- An electric pump mounted at the rear of the machine base ensures copious

flow of coolant to the work zone. The coolant is discharged into the built-in coolant tank

in the machine base.

LUBRICATION- Central lubrication for guide-ways and lead-screws, splash lubrication

for speed and feed gears.

GUIDES- The table, the cross-slide, and the knee, slide over dovetail guideways, which

are amply dimensioned to withstand machining load.

FEED & TRANSVERSE- Power-operated feed in longitudinal and cross directions for

standard Size 1 machine, rapid feed in longitudinal direction optional. Power operated

feed and rapid traverse in longitudinal, cross, and vertical directions for Size 2 and Size

3.5 models.

MOTORISED OVERARM- MOA is supplied with vertical milling head for Size 2 and Size

3.5 machines. The MOA comes with an independent drive motor of 3 kW (4 HP) power.

The spindle is provided with 12 speeds in the range 45-2,000. Since the MOA itself is

used as overarm for mounting

the arbor support bracket.

TABLE DRIVE- Lead-screw with

two nuts for backlash-free

setting Feed selection by sliding

gear drive Reversal of

movement direction through

motor reversal Dead accurate

stoppage through brake clutch

hange-over and rapid traverse

feed through multi-disc clutch.


34

CHARACTERISTICS

The width of the chip starts from zero and increases as the cutter finishes slicing. The tooth meets the workpiece at the bottom of the cut. Upward forces are created that tend to lift the workpiece during face milling. More power is required to conventional mill than climb mill. Surface finish is worse because chips are carried upward by teeth and dropped in front

of cutter. There's a lot of chip re-cutting. Flood cooling can help! Tools wear faster than with climb milling. Conventional milling is preferred for rough surfaces. Tool deflection during Conventional milling will tend to be parallel to the cut.

There are two major classes of milling process:

In face milling, the cutting action occurs primarily at the end corners of the milling cutter. Face milling is used to cut flat surfaces (faces) into the workpiece, or to cut flat-bottomed cavities.

In peripheral milling, the cutting action occurs primarily along the circumference of the cutter, so that the cross section of the milled surface ends up receiving the shape of the cutter. In this case the blades of the cutter can be seen as scooping out material from the work piece. Peripheral milling is well suited to the cutting of deep slots, threads, and gear teeth.


35

MACHINE LAYOUT


36

CHEVALIER SURFACE GRINDER- FSG-1228ADIII Automatic Precision Grinder

The highly advanced ADII series of automatic precision surface grinding machines are a

result of the on-going and extensive research and development program at

CHEVALIER In addition to improved accuracies, quality, and machine life, the overall

design of the machine incorporates ergonomics; all operating handwheels,levers,stroke

setting devices, and the pendant control panel are arranged to allow ease of operation,

therefore, working efficiency is increased.

A surface grinder is a machine tool used to provide precision ground surfaces, either to a

critical size or for the surface finish.The typical precision of a surface grinder depends

on the type and usage, however ±0.002 mm (±0.0001 in) should be achievable on most

surface grinders.The machine consists of a table that traverses both longitudinally and

across the face of the wheel. The longitudinal feed is usually powered by hydraulics, as

may the cross feed, however any mixture of hand, electrical or hydraulic may be used

depending on the ultimate usage of the machine (i.e., production, workshop, cost). The

grinding wheel rotates in the spindle head and is also adjustable for height, by any of

the methods described previously. Modern surface grinders are semi-automated, depth

of cut and spark-out may be preset as to the number of passes and, once set up, the

https://en.wikipedia.org/wiki/Grinding_machine

https://en.wikipedia.org/w/index.php?title=Ground_surfaces&action=edit&redlink=1

https://en.wikipedia.org/wiki/Hydraulic_machinery


37

machining process requires very little operator intervention.Depending on the workpiece

material, the work is generally held by the use of a magnetic chuck.

SPECIFICATION

DESCRIPTION FSG-1224ADIII FSG-1632ADIII FSG-1640ADII

Table Size 300x600mm 400x800mm 400x1000mm

(11 3/4"x23

5/8")

(15 3/4"x31 1/2") (15 3/4"x39 3/8")

Max. Grinding Length (Longitudinal) 610mm (24") 810mm (32") 1015mm (40")

Max. Grinding width (Crosswise) 305mm (12") 405mm (16")

Max. Distance from Table Surface to Spindle

Centerline

620mm (24 7/16 ")

Standard Magnetic Chuck Size 300x600mm

(11 3/4"x23

5/8")

400x800mm (15

3/4"x31 1/2")

400x1000mm

(15 3/4"x39 3/8")

Longitudinal Movement of Table Longitudinal Travel,

Hydraulic

650mm (25 5/8") 850mm (33 7/16") 1050mm (41

5/16")

Max Travel (Manual) 700mm (27 1/2") 900mm (35 3/8") 1100mm (43

1/4")

Table speed, variable 5~25m/min (16~82fpm)

Cross Transverse Travel Rapid travel (Approx.) 60Hz/3.5m/min (12fpm), 50Hz/2.9m/min (10fpm)

Auto transverse increment 3~32mm (1/8-1 1/4")

Max.automatic travel 12" (305mm) 405mm (16")

Max. manual travel 350mm (13 3/4") 460mm (18")

Handwheel per revolution 6mm (0.25")

Handwheel per graduation 0.1mm (0.0025")

Micro

feed

per revolution 0.1mm (0.005")

per graduation 0.001mm (0.00005")

Wheelhead vertical infeed Auto infeed 0.001~0.04mm (0.00005" ~0.002")

Rapid travel (Approx.) 500mm/min (25 ipm)

Standard Grinding Drive Speed 60Hz/1750rpm,50Hz/1450rpm

Power Rating 5HP/4P

Standard Grinding Wheel Diameter 355mm (14")

Width 50mm (2")

Bore 127mm (5")

Floor Space (Lx Wx H) 2950x 3340x 4280x

1490x2080mm 1730x2080mm 1730x2080mm

(116"x59"x81 7/8 (139"x68"x81 7/8 ") (158"x68"x76")


38

OPTONAL-

Machine lamp.

Grinding wheel.

Chuck controller.

Wheel flange.

Parallel dressing attachment

(manual type).

Dual face dresser adapter for

mounting diaformdresser.

Universal wheel guard &

nozzle.

Balancing stand with levellingbubble .

Balancing stand (roller type).

Single face dresser.

Electromagnetic chuck.

Over-the-wheel auto. Straight line dressing & compensation device.

Parallel dressing attachment (hydraulic).

Rotary diamond dresser .

Single side water baffle saddle locking device frequency converter for spindle.

Dust collector.

Coolant system with double filter.

Coolant system with auto. Paper feeding device & magnetic separator (with 1roll

of paper).

Coolant system with auto. Paper feeding device (with 1 roll of paper).

Coolant system with manual paper feeding device

MACHINE LAYOUT


39

CONVENTIONAL LATHE- Four Jaw Chuck Conventional Lathe Machine

A lathe is a machine tool which rotates the workpiece on its axis to perform various

operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning,

with tools that are applied to the workpiece to create an object which has symmetry

about an axis of rotation. Lathes are used in woodturning, metalworking, metal spinning,

thermal spraying, parts reclamation, and glass-working. Lathes can be used to shape

pottery, the best-known design being the potter's wheel. Most suitably equipped

metalworking lathes can also be used to produce most solids of revolution, plane

surfaces and screw threads or helices. Ornamental lathes can produce three-

dimensional solids of incredible complexity. The workpiece is usually held in place by

either one or two centres, at least one of which can typically be moved horizontally to

accommodate varying workpiece lengths. Other work-holding methods include clamping

the work about the axis of rotation using a chuck or collet, or to a faceplate, using

clamps-or-dogs.


40

Examples of objects that can be produced on a lathe include candlestick holders, gun

barrels, cue sticks, table legs, bowls, baseball bats, musical instruments (especially

woodwind instruments), crankshafts, and camshafts.

Lathes have allowed man to reshape, machine and manufacture many precision

cylindrical components made of various types of metal, wood, plastics, and other

materials. Without the lathe, man would still be trying to produce cylindrical components

in some crude fashion or another. However, because of advanced technology, the lathe

has allowed man to become an important asset in developing and machining many

precision components needed to operate and function in many areas of our industrial

complex.


41

TATA Motors has a 4 jaw manual centring lathe machine, which could

be widely used for several operations and is self-sufficient for a wide

range of jobs. Although it is old but does all the work precisely as has

no electrical component or CNC grid so problem occurs. It is water

resistant and coolant/lubricant tray makes the flow continuous.

LATHE MACHINE TOOLS

MODES OF USES

When a workpiece is fixed between the headstock and the tail-stock, it is said to be "between

centres". When a workpiece is supported at both ends, it is more stable, and more force may be

applied to the workpiece, via tools, at a right angle to the axis of rotation, without fear that the

workpiece may break loose. When a workpiece is fixed

only to the spindle at the headstock end, the work is

said to be "face work". When a workpiece is supported

in this manner, less force may be applied to the

workpiece, via tools, at a right angle to the axis of

rotation, lest the workpiece rip free.


42

LATHE OPERATIONS


43

GOODWAY CNC TURNING- POWER LATHE CNC FOR BETTER PRECISION

A metal lathe or metalworking lathe is a large class of lathes designed for precisely

machining relatively hard materials. They were originally designed to machine metals;

however, with the advent of plastics and other materials, and with their inherent

versatility, they are used in a wide range of applications, and a broad range of materials.

In machining jargon, where the larger context is already understood, they are usually

simply called lathes, or else referred to by more-specific subtype names (toolroom lathe,

turret lathe, etc.). These rigid machine tools remove material from a rotating workpiece

via the (typically linear) movements of various cutting tools, such as tool bits and drill

bits. The design of lathes can vary greatly depending on the intended application;

however, basic features are common to most types. These machines consist of (at the

least) a headstock, bed, carriage, and tailstock. Better machines are solidly constructed

with broad bearing surfaces (slide-ways) for stability, and manufactured with great

precision. This helps ensure the components manufactured on the machines can meet

the required tolerances and repeatability.

Various other codes are also used. A CNC machine is operated by a single operator

called aprogrammer. This machine is capable of performing various operations

automatically and economically. With the declining price of computers and open source

CNC software, the entry price of CNC machines has plummeted. Computer numerical

controlled (CNC) lathes are rapidly replacing the older production lathes (multispindle,

etc.) due to their ease of setting, operation, repeatability and accuracy. They are

designed to use

modern carbide

tooling and fully use

modern processes.

The part may be

designed and the tool

paths programmed by

the CAD/CAM

process or manually

by the programmer,

and the resulting file

https://en.wikipedia.org/wiki/Lathe


https://en.wikipedia.org/wiki/Metal

https://en.wikipedia.org/wiki/Plastic

https://en.wikipedia.org/wiki/Jargon

https://en.wikipedia.org/wiki/Machine_tool

https://en.wikipedia.org/wiki/Rotation

https://en.wikipedia.org/wiki/Linear_motion

https://en.wikipedia.org/wiki/Tool_bit

https://en.wikipedia.org/wiki/Drill_bit



https://en.wikipedia.org/wiki/CNC#DIY.2C_hobby.2C_and_personal_CNC



https://en.wikipedia.org/wiki/Computer_numerical_control



https://en.wikipedia.org/wiki/Tungsten_carbide

https://en.wikipedia.org/wiki/Computer-aided_technologies


44

uploaded to the machine, and once set and trialled the machine will continue to turn out

parts under the occasional supervision of an operator. The machine is controlled

electronically via a computer menu style interface, the program may be modified and

displayed at the machine, along with a simulated view of the process. The

setter/operator needs a high level of skill to perform the process, however the

knowledge base is broader compared to the older production machines where intimate

knowledge of each machine was considered essential. These machines are often set

and operated by the same person, where the operator will supervise a small number of

machines (cell).

The design of a CNC lathe varies with different manufacturers, but they all have some

common elements. The turret holds the tool holders and indexes them as needed, the

spindle holds the workpiece and there are slides that let the turret move in multiple axis

simultaneously. The machines are often totally enclosed, due in large part to

occupational health and safety (OH&S) issues.

With rapid growth in this industry, different CNC lathe manufacturers use different user

interfaces which sometimes makes it difficult for operators as they have to be

acquainted with them. With the advent of cheap computers, free operating systems

such as Linux, and open source CNC software, the entry price of CNC machines has

plummeted.

https://en.wikipedia.org/wiki/Occupational_safety_and_health

https://en.wikipedia.org/wiki/Linux

https://en.wikipedia.org/wiki/Open_source


45

Feed mechanisms

Various feed mechanisms exist to feed material into a lathe at a defined rate.

Bar feeder

A bar feeder feeds a single piece of bar stock into the cutting machine. As each part is machined, the cutting tool creates a final cut to separate the part from the bar stock, and the feeder continues to feed the bar for the next part, allowing for continual operation of the machine.

Bar loader

A bar loader is a variation on the bar feeder concept in that multiple pieces of bar stock may be fed into a hopper, and the loader feeds each piece as necessary.

CONTROL UNIT CHUCK

There are many variants of lathes within the metalworking field. Some variations are not

all that obvious, and others are more a niche area. For example, a centering lathe is a

dual head machine where the work remains fixed and the heads move towards the

workpiece and machine a center drill hole into each end. The resulting workpiece may

then be used "between centers" in another operation

PRODUCT

https://en.wikipedia.org/wiki/Bar_stock

https://en.wikipedia.org/wiki/Metalworking


46

ITL POWER SAW- POWER BAND TYPE SAW FOR LARGE LATERAL SECTIONS

A hacksaw is a fine-toothed saw, originally and principally for cutting metal. They can also cut various other materials, such as plastic and wood; for example, plumbers and electricians often cut plastic pipe and plastic conduit with them. There are hand saw versions and powered versions (power hacksaws). Most hacksaws are hand saws with a C-shaped frame that holds a blade under tension. Such hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. The frames may also be adjustable to accommodate blades of different sizes. A screw or other mechanism is used to put the thin blade under tension. Panel hacksaws forgo the frame and instead have a sheet metal body; they can cut into a sheet metal panel further than a frame would allow. These saws are no longer commonly available, but hacksaw blade

holders enable standard

hacksaw blades to be used similarly to a keyhole saw or pad saw.

Power tools including

nibblers, jigsaws, and angle grinders fitted with metal-cutting blades and discs are now used for longer cuts in sheet metals. A power hacksaw (or electric hacksaw) is a

type of hacksaw that is powered either by its own electric motor or connected to a stationary engine. Most power hacksaws are stationary machines but some portable models do exist; the latter (with frames) have been displaced to some extent by reciprocating saws such as the Sawzall, which accept blades with hacksaw teeth. Stationary models usually have a mechanism to lift up the saw blade on the return stroke and some have a coolant pump to prevent the saw blade from overheating.

Power hacksaws are not as commonly used in the metalworking industries as they once were. Bandsaws and cold saws have mostly displaced them. While stationary electric hacksaws are not very common, they are still produced. Power hacksaws of the type powered by stationary engines and line shafts, like other line-shaft-powered machines, are now rare; museums and antique-tool hobbyists still preserve a few of them.

https://en.wikipedia.org/wiki/Electric_motor

https://en.wikipedia.org/wiki/Stationary_engine

https://en.wikipedia.org/wiki/Reciprocating_saw

https://en.wikipedia.org/wiki/Bandsaw

https://en.wikipedia.org/wiki/Cold_saw

https://en.wikipedia.org/wiki/Line_shaft


47

PROPERTIES

• Cutting arm of high tension bearing capacity with preloaded adjustable antifriction

ball bearings

• Cutting arm guided in vertical plate, self lubricated due to grease packing.

• Protected from atmosphere.

• 6 cutting speeds with dual speed motor (Optional).

• Infinitely variable feed rate and positive hydraulic cutting pressure.

• Motorized hydraulic pump for faster approach of blade to job.

• Full cutting efficiency by positive feed pressure.

• Forward cutting operation by hydraulic pressure.

• New tech HSS bi-metal blade with a tooth hardness of 67 HRC can also be used.

• In case of hydraulic failure, blades & job are saved automatically.

PRODUCTS OF ITL


48

RADIAL DRILLING MACHINE- Self-Feeding Radial Drilling Heavy Duty Machine

A radial drilling machine or radial arm press is a geared drill head that is mounted on an

arm assembly that can be moved around to the extent of its arm reach. The most

important components are the arm, column, and the drill head. The drill head of the

radial drilling machine can be moved, adjusted in height, and rotated. Aside from its

compact design, the radial drill press is capable of positioning its drill head to the work

piece through this radial arm mechanism. This is probably one of the reasons why more

machinists prefer using this type of drilling machine. In fact, the radial drilling machine is

considered the most

versatile type of drill

press. The tasks that a

radial drilling machine

can do include boring

holes, countersinking,

and grinding off small

particles in masonry

works.Although some

drill presses are floor

mounted, the most

common set-up of

radial arm drill presses

are those that are

mounted on work

benches or tables. With

this kind of set-up, it is

easier to mount the drill

and the work pieces.

There is no need to

reposition work pieces

because the arm can extend as far as its length could allow. Moreover, it is easier to

manoeuvre large work pieces with the radial arm drilling machine. Large work pieces

can be mounted on the table by cranes as the arm can be swivelled out of the way.


49

Here are some of the major parts of the radial arm drilling machine:

Column -is the part of the radial arm drill press which holds the radial arm which can be

moved around according to its length

Arm Raise - adjusts the vertical height of the radial arm along the column

On/Off Button - is the switch that activates and deactivates the drill press

Arm Clamp - secures the column and the arm in place

Table - is the area where the work pieces are fed and worked on

Base - is the radial arm drill press part that supports the column and the table

Spindle - is the rotated part of the drill press which holds the drill chuck used in holding

the cutting tool.

Drill Head - is the part of the drill press that penetrates through the material or work

piece and drill through the specific hole size

Radial Arm - holds and supports the drill head assembly and can be moved around on

the extent of its length

There are a number of advantages of using the radial arm drill press. One of these

advantages is the amount of area that it can cover which is only dependent on the

length of the arm. Another advantage is the considerable size of work that it can handle

since the arm can

actually swivel out of

the working area

allowing cranes and

derricks to place

work pieces on the

table. Finally, less

effort is required

during the drilling

process because the

arm assembly

seemingly is doing

all that is needed for

specific tasks to be

completed.


50

RADIAL DRILL LAYOUT

DRILLING OPERATIONS

Threading

Reaming

Drilling

Counter Sinking

Boring

Counter Boring

Tapping

Trepanning

Spot Facing

Drill Bit of size 0.2 – 102mm Is used. Coolant used is soluble oil mixed with water,

basically fatty, immersive oils etc.


51

STUDER S242- CNC CYLINDERICAL GRINDER

This is the Studer CNC Grinder which is capable of grinding the job whatsoever

internally or externally both simultaneously. With a tolerance of 1 micron the machine is

capable of grinding basically cylindrical jobs mostly with the internal and external

grinding wheels. The input is entered in the form of G-Code according to the job. Two

Third bore required for minimum diameter of the job.

BENEFITS

The S242combined machine

tool ideally combines the

technologies of cylindrical

grinding and hard turning.

Thanks to its design concept,

it can easily cope with both

processes. Consequently, it

enables highly efficient hard

fine machining of shafts and

chucking components with a

high manufacturing quality,

production reliability and the desired surface quality in a single clamping. It is interesting

not only for high-volume production but also for small batch sizes and single parts.

INNER GRINDING WHEELS CONTROL


52

TECHNICAL SPECIFICATIONS

Distance between centres 400/800/1000 mm

Swing diameter 180 mm

Synchronous tailstock with selectable axial clamping pressure for workpiece drive

definable for each workpiece in the workpiece program

Multiple in-process gauging. Individual workpiece positions and diameters are stored in

the workpiece program.

Machine bed with inclined design (machining plane 45°) made from GRANITAN®

Standardized interfaces for loader and peripheral devices

Automated part handling system (option)

Easy programming thanks to StuderWIN

Full enclosure with sliding door

The modular kit system enables customer-specific designs

Large range of accessories


53

MACHINE

LAYOUT


54


55

DECKEL MAHO- GILDEMEISTER DMU 80 T MACHINING CENTER-UNIVERSAL

One of the most efficient machines in the PE Shop at Tata, Lucknow is this Universal Milling

Machine of Deckel Mahobrought up nearly 15years ago from Germany, has an automatic

changer which according to the need changes the tool instantaneously. This is hence a CNC

machine works on several Servo motors functioning to 4axles in 5 side machining. Consists of

two heads- upper & lower; which can be easily interchanged for horizontal or vertical milling

activity. The table below on which the job is been placed rotates hence for the better job finish

and precision is much greater than any other milling. The only demerit is that a very huge job

can‟t be machined on it because of the smaller size of the machine. The job must be kept

150mm distance from the tool. The coolant system is automated as to cool the tool precisely

and act as lubrication for the machining. The machine has firstly to be entered with the proper

G-Code (CNC program) according to the job specification manually and then the further

automated milling machine does everything.

Most CNC milling machines (also called machining centres) are computer controlled vertical

mills with the ability to move the spindle vertically along the Z-axis. This extra degree of freedom

permits their use in die sinking, engraving applications, and 2.5D surfaces such

as relief sculptures. When combined with the use of conical tools or a ball nose cutter, it also

https://en.wikipedia.org/wiki/CNC

https://en.wikipedia.org/wiki/2.5D_(machining)

https://en.wikipedia.org/wiki/Relief

https://en.wikipedia.org/wiki/Milling_cutter#Ball_nose_cutter


56

significantly improves milling precision without impacting speed, providing a cost-efficient

alternative to most flat-surface hand-engraving work.

CNC machines can exist in virtually any of the forms of manual machinery, like horizontal mills.

The most advanced CNC milling-machines, the multiaxis machine, add two more axes in

addition to the three normal axes (XYZ).[8] Horizontal milling machines also have a C or Q axis,

allowing the horizontally mounted work piece to be rotated, essentially allowing asymmetric

and eccentric turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of these

axes are used in conjunction with each other, extremely complicated geometries, even organic

geometries such as a human head can be made with relative ease with these machines. But the

skill to program such geometries is beyond that of most operators. Therefore, 5-axis milling

machines are practically always programmed withCAM.

The operating system of such machines is a closed loop system and functions on feedback.

These machines have developed from the basic NC (NUMERIC CONTROL) machines. A

computerized form of NC machines is known as CNC machines. A set of instructions (called a

program) is used to guide the machine for desired operations. Some very commonly used

codes, which are used in the program, are:

G00 - Rapid Traverse

G01 - linear interpolation of tool.

G21 - Dimensions in metric units.

M03/M04 - spindle start (clockwise/counter clockwise).

T01 M06 - Automatic tool change to tool 1

M30 - program end.

Various other codes are also used. A CNC machine is operated by a single operator called

aprogrammer. This machine is capable of performing various operations automatically and

economically.

With the declining price of computers and open source CNC software, the entry price of CNC

machines has plummeted.

https://en.wikipedia.org/wiki/Engraving



https://en.wikipedia.org/wiki/Multiaxis_machining

https://en.wikipedia.org/wiki/Milling_(machining)#cite_note-8

https://en.wikipedia.org/wiki/Eccentric_(mechanism)

https://en.wikipedia.org/wiki/Turning

https://en.wikipedia.org/wiki/Axis_of_rotation

https://en.wikipedia.org/wiki/Computer-aided_manufacturing



57

TOOLS LAYOUT


58

BFW MACHINE- CNC MILLING MACHINE VERTICAL

Milling is the machining process of using rotary cutters to remove material[1] from a

workpiece advancing (or feeding) in a direction at an angle with the axis of the tool.[2][3]

It covers a wide variety of different operations and machines, on scales from small

individual parts to large, heavy-duty gang milling operations. It is one of the most

commonly used processes in industry and machine shops today for machining parts to

precise sizes and shapes.

Milling can be done with a wide range of machine tools. The original class of machine

tools for milling was the milling machine (often called a mill). After the advent of

computer numerical control (CNC), milling machines evolved into machining centers

(milling machines with automatic tool changers, tool magazines or carousels, CNC

control, coolant systems, and enclosures), generally classified as vertical machining

centers (VMCs) and horizontal machining centers (HMCs). The integration of milling into

turning environments and of turning into milling environments, begun with live tooling for

lathes and the occasional use of mills for turning operations, led to a new class of

machine tools, multitasking machines (MTMs), which are purpose-built to provide for a


https://en.wikipedia.org/wiki/Milling_cutter

https://en.wikipedia.org/wiki/Milling_%28machining%29#cite_note-FOOTNOTEBrown_.26_Sharpe19147-1

https://en.wikipedia.org/wiki/Milling_%28machining%29#cite_note-FOOTNOTECMMC1922122-2




https://en.wikipedia.org/wiki/Numerical_control

https://en.wikipedia.org/wiki/Turning


59

default machining strategy of using any combination of milling and turning within the

same work envelope. A metal lathe or metalworking lathe is a large class of lathes

designed for precisely machining relatively hard materials. They were originally

designed to machine metals; however, with the advent of plastics and other materials,

and with their inherent versatility, they are used in a wide range of applications, and a

broad range of materials. In machining jargon, where the larger context is already

understood, they are usually simply called lathes, or else referred to by more-specific

subtype names (toolroom lathe, turret lathe, etc.). These rigid machine tools remove

material from a rotating workpiece via the (typically linear) movements of various cutting

tools, such as tool bits and drill bits. The design of lathes can vary greatly depending on

the intended application; however, basic features are common to most types. These

machines consist of (at the least) a headstock, bed, carriage, and tailstock. Better

machines are solidly constructed with broad bearing surfaces (slide-ways) for stability,

and manufactured with great

precision. This helps ensure

the components

manufactured on the

machines can meet the

required tolerances and

repeatability.

NC milling is a specific form

of computer numerical

controlled (CNC) machining. Milling itself is a machining process similar to both drilling

and cutting, and able to achieve many of the operations performed by cutting and

drilling machines. Like drilling, milling uses a rotating cylindrical cutting tool. However,

the cutter in a milling machine is able to move along multiple axes, and can create a

variety of shapes, slots and holes. In addition, the work-piece is often moved across the

milling tool in different directions, unlike the single axis motion of a drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are

grouped by the number of axes on which they operate, which are labeled with various

letters. X and Y designate horizontal movement of the work-piece (forward-and-back

and side-to-side on a flat plane). Z represents vertical, or up-and-down, movement,

while W represents diagonal movement across a vertical plane. Most machines offer

from 3 to 5 axes, providing performance along at least the X, Y and Z axes. Advanced

https://en.wikipedia.org/wiki/Lathe


https://en.wikipedia.org/wiki/Metal

https://en.wikipedia.org/wiki/Plastic

https://en.wikipedia.org/wiki/Jargon


https://en.wikipedia.org/wiki/Rotation

https://en.wikipedia.org/wiki/Linear_motion

https://en.wikipedia.org/wiki/Tool_bit



60

machines, such as 5-axis milling centers, require CAM programming for optimal

performance due to the incredibly complex geometries involved in the machining

process.

Computer numeric controlled machining centers are used to produce a wide range of

components, and tooling costs involved have continued to become more affordable. In

general, large production runs requiring relatively simple designs are better served by

other methods, although CNC machining can now accommodate a wide range of

manufacturing needs. CNC milling centers are ideal solutions to everything ranging from

prototyping and short-run production of complex parts to the fabrication of unique

precision components. Virtually every type of material that can be drilled or cut can be

machined by a CNC mill, although most of the work performed is done in metal. As with

drilling and cutting, the proper machine tools must be selected for each material in order

to avert potential problems. The hardness of the work-piece material, as well as the

rotation of the cutting tool must all be factored before beginning the machining process.


61

The operating system of such

machines is a closed loop system and

functions on feedback. These

machines have developed from the

basic NC (NUMERIC CONTROL)

machines. A computerized form of NC

machines is known as CNC machines.

A set of instructions (called a program)

is used to guide the machine for

desired operations. When combined

with the use of conical tools or a ball

nose cutter, it also significantly

improves milling precision without

impacting speed, providing a cost-

efficient alternative to most flat-surface

hand-engraving work

MACHINE LAYOUT

https://en.wikipedia.org/wiki/Cone_%28geometry%29




https://en.wikipedia.org/wiki/Engraving


62

TANAKA GAS CUTTER- GAS CUTTER AND PHOTO TRACER TYPE

Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding

in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld

and cut metals, respectively. French engineers Edmond Fouché and Charles Picard

became the first to develop oxygen-acetylene welding in 1903. Pure oxygen, instead of

air, is used to increase the flame temperature to allow localized melting of the workpiece

material (e.g. steel) in a room environment. A common propane/air flame burns at about

2,250 K (1,980 °C; 3,590 °F), a propane/oxygen flame burns at about 2,526 K (2,253

°C; 4,087 °F), and an acetylene/oxygen flame burns at about 3,500 °C (6,330 °F).

Oxy-fuel is one of the

oldest welding

processes, besides

forge welding. Still

used in industry, in

recent decades it has

been less widely

utilized in industrial

applications as other

specifically devised

technologies have

been adopted. It is still

widely used for

welding pipes and tubes, as well as repair work. It is also frequently well-suited, and

favoured, for fabricating some types of metal-based artwork. As well, oxy-fuel has an

advantage over electric welding and cutting processes in situations where accessing

electricity (e.g., via an extension cord or portable generator) would present difficulties; it

is more self-contained, and, hence, often more portable.

Butane, like propane, is a saturated hydrocarbon. Butane and propane do not react with

each other and are regularly mixed. Butane boils at 0.6 °C. Propane is more volatile,

with a boiling point of -42 °C. Vaporization is rapid at temperatures above the boiling

points. The calorific (heat) values of both are almost equal. Both are thus mixed to attain

the vapour pressure that is required by the end user and depending on the ambient

https://en.wikipedia.org/wiki/Butane


63

conditions. If the ambient temperature is very low, propane is preferred to achieve

higher vapour pressure at the given temperature.

Propane does not burn as hot as acetylene in its inner cone, and so it is rarely used for

welding Propane, however, has a very high number of BTUs per cubic foot in its outer

cone, and so with the right torch (injector style) can make a faster and cleaner cut than

acetylene, and is much more useful for heating and bending than acetylene. The

maximum neutral flame temperature of propane in oxygen is 2,822 °C (5,112 °F).

Propane is cheaper than acetylene and easier to transport. Like propylene, most

propane tips are of a two-piece design. Propane often gets unfair criticism because it

really needs changing the torch (from an equal pressure torch to an injector torch) and

not just changing the tip to get the best performance. Most torches are equal pressure

and designed for gases, such as acetylene, which are lighter than oxygen. Propane is a

great deal heavier and runs much better through a low-pressure injector torch with a

setting from a few ounces to about two pounds per square inch when cutting.

https://en.wikipedia.org/wiki/Oxy-fuel_welding_and_cutting#Injector_torch


64


65

MUFFLE FURNACE- HEAT TREATMENT PROCESS OF THE METAL

A muffle furnace (sometimes, retort furnace) in historical usage is a furnace in which the

subject material is isolated from the fuel and all of the products of combustion including

gases and flying ash. After the development of high-temperature electric heating

elements and widespread electrification in developed countries, new muffle furnaces

quickly moved to electric designs. Today, a muffle furnace is (usually) a front-loading

box-type oven or kiln for high-temperature applications such as fusing glass, creating

enamel coatings, ceramics and soldering and brazing articles. They are also used in

many research facilities, for example by chemists in order to determine what proportion

of a sample is non-combustible and non-volatile (i.e., ash). Some digital controllers

allow RS232 interface and permit the operator to program up to 126 segments, such as

ramping, soaking, sintering, and more. Also, advances in materials for heating

elements, such as molybdenum disilicide, can now produce working temperatures up to

1,800 degrees Celsius (3,272 degrees Fahrenheit), which facilitate more sophisticated

metallurgical applications. The term muffle furnace may also be used to describe

another oven constructed on many of the same principles as the box type kiln

mentioned above, but takes the form of a long, wide, and thin hollow tube used in roll to

roll manufacturing processes. Both of the above mentioned furnaces are usually heated

to desired temperatures by conduction, convection, or blackbody radiation from

electrical resistance heating elements. Therefore there is (usually) no combustion

involved in the temperature control of the system, which allows for much greater control


66

of temperature uniformity

and assures isolation of

the material being heated

from the by-products of

fuel combustion.

An Automatic Oil Muffle

Furnace, circa 1910.

Petroleum is contained in

tank A, and is kept under

pressure by pumping at

intervals with the wooden

handle, so that when the

valve B is opened, the oil

is vaporized by passing

through a heating coil at

the furnace entrance, and

when ignited burns

fiercely as a gas flame.

This passes into the

furnace through the two

holes, C, C, and plays

under and up around the

muffle D, standing on a

fireclay slab. The doorway

is closed by two fireclay

blocks at E.


67

TOOL HEIGHT MACGINE- TOOL HEIGHT MEASURING MACHINE

Basically used to measure the tool length before the usage of the tool and even every

time after the tool was used. The tool gets rusted or been grinded while getting been

used. This is basically very important for the CNC machines as they do require the

actual length of the tool for the further numerical calculations and the measurements.


68

Case Study I: - Oil Sumps for Engines This Case study gives an insight on how the part design can be

simplified by optimization in virtual tryout / simulation. Oil sumps of

various Tata Motors projects were made feasible using virtual tryout

tools. The learning from these exercises were documented to enable

product designers to design oil-sumps to engine requirements in

shortest possible virtual tryout loops.

The exercise made possible Implementation of 3-Ply Sandwich

material for special NVH (Noise, Vibrations and Harshness)

application in one of the Oil Sumps.


69

Case Study II: - Head Lamp Cover for a Tata Mini Truck Initial Head lamp cover was made up of 2 stamping parts joined by

spot welding. Due to number of joints the head lamps cover was

prone to leakages. After studying various possible solutions a cost-

effective, single piece design had been proposed and implemented

successfully.


70

Case Study III: - Simultaneous Engineering

for Manufacturing Feasibility

As per the Simultaneous Engineering concept, all design activities

should occur simultaneously, the overall goal being that the

concurrent nature of these processes significantly reduces project

implementation time while increasing productivity and product quality.

The success of Simultaneous Engineering lies in allowing errors and

redesigns to be discovered early during the design process when the

project is still in a more abstract and digital realm. By locating and

fixing these issues early, the design team can avoid costly errors as

the project moves to more complicated computational models and

eventually into the physical realm.


71

Case Study IV: Dimensional Variation Analysis (DVA) of Using 3DCS Software on CATIA V5 R19 Platform

Dimensional Variation Analysis helps in closing the gap between

engineering investigation and manufacturing quality assurance. The

challenge is to integrate such components without experiencing

significant production problems so as to reduce costs and deliver

products in the market faster and better. By leveraging the

advantages of 3DCS CatiaV5, variation analysis, reduction of

assembly flow time and recurring costs resulting from rework and

adjustments late in the production cycle can be achieved.


72

LEARNING From this Production Engineering Department Case Study we can learn

few very basic and important learning‟s. That the PE department is really

very important and is the only which consists of a lot of machines and

equipment for the manufacturing processes.

PE's commercial operations started in 2001-2002 and since then have

done tooling works for several OEM and Tier 1 companies in India and

Europe.

With knowledge of vehicle level fitments and engineering in tool making,

which is an added benefit to its customers, PE division is aiming to reduce

project risks and efficiently manage timelines.

PE plays a very important role in BIW tooling of Tata Motors Limited

through its New Product Development process.

PE's product portfolio comprises Stamping Dies (Press Tools), Sheet-Metal

Fixtures, Inspection Fixtures and Gauges, Foundry Tooling and

Thermoforming Moulds.

tata-proj

Documents

Transcript of tata-proj