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Industrial Training Presentation onManufacturing of Engine and Transmission Componentsat

1History of Yamaha Motors India 1955 Genichi Kawakami founded Yamaha Motors. YA-1 was the first bike manufactured in 125cc.

Genichi Kawakami The YA-1

1965 Manufacturing activities shifted to the present building of Faridabad Plant.

1984 Setup Plant in Surajpur near delhi jointly with Escorts.

1985 Started manufacturing of RX-100 cc Motorcycle with technical collaboration with Yamaha Motors Company of Japan, at Surajpur plant.

2009 Assembly lines at Surajpur were installed and spread over an area of 36,000 sq. mts. It has the capacity to produce 1 million motorcycles and scooters annually.

INDIA YAMAHA MOTORS In India, Yamaha has three PlantsMachine shopFaridabad Plant has In-house facility for Machining, Casting, Paint, Hardening and Electroplating.Its Machine shop is well equipped with latest CNC and VMC Machines making it capable of Producing every components.It Produces various Components like Head & Body Cylinder, Gears, Crank, Camshaft, Axles, Crankcase.

Head Cylinder Cylinder Block is made into two parts :- 1. Head Cylinder 2. Body Cylinder

Head cylinder plays a important role in combustion as it contains the combustion chamber and guide mechanism for the fuel to be entered for combustion.

It also contains :- 1. Inlet and Outlet valves 2. Cam and rocker assembly 3. Spark Plug

Fig. Head Cylinder

Spark plug OpeningInlet ValveOutlet ValveTiming Chain SlotCam shaft and its Bearing

BODY CYLINDER Body Cylinder is a part of the Cylinder Block. It mainly encloses the cylinder in which piston moves and provision for liquid cooling.

Fig. Body Cylinder

Passage for CoolantCylinder Tapping for STUDS Its Functions :- To ensure proper functioning of the piston inside the cylinder. It also dissipate heat to the atmosphere preventing the heating of the engine It also subjected to various pressure that has been developed due to the combustion of the fuel inside the cylinder.

Materials Used :- Yamaha uses two materials for body cylinder :- 1. Aluminium (have steel liner) 2. DiASil (no need of steel liner)

What is DiASil Cylinder ?

Problem Encountered :-

The cylinder wall is exposed to constant friction from the piston, a steel sleeve is inserted in the cylinder to achieve high abrasion resistance. If the sleeve is eliminated in order to improve heat dissipation, the aluminum cylinder by itself doesnt have the strength to provide sufficient abrasion resistance.

Solution :-

To solve this problem DiASil Cylinder adds a silicon content of 20% (twice that of regular aluminum) to the aluminum alloy to achieve the required hardness to resist abrasion.

Benefits of DiASil Cylinder :-It is lighter and has better cooling performance. No need of a steel sleeve because it is made of abrasion-resistant aluminum alloy.Has a heat dissipation rate that is three times better than steel, which means great cooling performance

Manufacturing Process on Body CylinderFacing of both sides DrillingReaming of drillsFace milling and dowel drillingInspection of Dimensions (done with the help of air guages)HonningLeakage CheckHonningHoning improves cylinder performance by producing more uniform and controlled bore geometry, size and surface finish

It is also used to make hatches inside cylinder

It is done so that the lubricating oil stucks in the hatches, thus improving the lubrication.

Hatching angle lies in 15-30.

Air GaugesAir gaging is a non-contact means of precise comparative dimensional measurementIt is ideal for measuring dimensions with tolerances smaller than .005", and when gaging tight tolerances, a resolution as small as .000002" can be achieved.

Working

Air gaging relies on the laws of physics which state that flow and pressure are directly proportionate to clearance and they react inversely to each other.

The regulated air flows through the restriction a needle valve, jeweled orifice, etc. and then through the nozzle. When the nozzle is open to the atmosphere, there is maximum flow through it and there is a minimum of pressure called back-pressure between the restriction and the nozzle.

As an obstruction is brought increasingly close to the front of the nozzle, air flow from the nozzle diminishes and back pressure builds. When the nozzle is completely obstructed, air flow is zero, and back-pressure reaches the pressure of the regulated air supply.

CRANK It is used to convert the reciprocating motion of the piston into the rotatory motion. It transmits power that is obtained after the combustion of fuel in the cylinder to the transmission and dynamo. It is used in balancing of engines to reduce vibrations.

Hole for Crank pinCrank to transmissionDynamo Side CrankKey wayCONNECTING ROD It is used to connect the piston and the crankshaft and transmit the power from the piston to the crank. It has two ends :- 1. Small End 2. Big End Small End is Connected to the piston and Big End is connected to the crankshaft.

CAM Cam is a mechanical component which is used to convert rotatary motion into reciprocating or oscillating motion.In engines, it is used to actuate the inlet and outlet valves

BearingCAM LobesTiming SprocketGEARGears are toothed wheels which transmit power and motion from one shaft to another by means of successive engagement of teeth.Classification of gears used in gear box :- 1. Spur Gears 2. Helical Gears

AXLESAxles are used to provide support to the gear and to transmit power to the gears from the engine. Sometimes, on axles teeths have been cut in order to mesh directly with the pinion or gear.There are two axles used in gear box :- 1. Primary Drive 2. Axle DriveManufacturing of Gears and AxlesTurningHobbingDeburringShavingCentre drillOuter Diameter GrindingInduction TemperingKeyway Cutting

After these processes, further processes carried out which includes :-

1. Induction Hardening of Gear and axles used to increase the hardness of the surface of gears so that the steel balls do not impinges inside the surface of the gearAlso used to increase the hardness of the splines cut on the gear and axles.

2. Shot Blasting.

Shot Blasting Shot Blasting is a surface treatment process using high velocity steel abrasive. The components placed on the rotary table are continuously passed through the blasting zone. This guarantees a uniform blasting of the surface. In general shot blasting concentrates abrasive particles at high speed (65-110 m/second) in a controlled manner at the material thereby removing surface contaminates due to the abrasive impact.

Shot blasting systems are comprised of 4 basic subsystems: 1. Abrasive delivery method: a. By Compressed Air. b. By Centrifugal turbines. 2. Abrasive recovery and cleaning. 3. Dust collection. 4. Blast Cabinet.

Shot blasting is commonly used for : The cleaning of iron, steel, non-cast parts, forgings, etc. Shot peening to alter mechanical properties (increasing resistance to fatigue for springs, gears, etc.) Mechanical cleaning of sheets, rods, coils, wire, etc. Preparing surfaces to be painted, coated, etc.

Before Shot blasting After Shot Blasting

Fig. Transmission AssemblyTHANK YOU

Submitted To:Mrs. PRATIBHA KARWALMr. AJAY SINGH VERMASubmitted By:NITIN KUMAR (1102940068)