ESCORTS AGRI MACHINERY GROUP

INDUSTRIAL PROJECT

SUBMITTED BY:
NAME - SUNIL TANWER
COLLEGE - ADVANCED INSTITUTE OF
TECH & MNGT, PALWAL
BRANCH - MECHANICAL ,2ND YEAR
DATE - 30 JUNE ,2010
 ACKNOWLEDGEMENT
I would like to thank to all those with whom I worked and whose
thoughts and insights helped me in increasing my knowledge and
understanding of working in the organization.

I would like to pay my sincere gratitude to MR. SUNIL SANDHU, MR.

A.K WADHWA & all employees, my project guide, who helped me
during the course of my training by providing his valuable suggestion,
ideas and guidance which proved beneficial for completion of my
project.

Besides I would also thank to all the supervisors, Foreman and workers
who helped me to understand the depth of my project, what they want
out of the project.

These people made me comfortable to understand the functioning of

each machine & about the operation occuring on the machines.

They tried their best to make me understand about the fixtures, tools and
gauges used on the machine. These peoples never made me feel as a
trainee in the department rather provide an atmosphere like a family and
feel proud being the part of their through for short while.

Without their help this project would never have taken its present form.
In fact this project is the result of their vision, optimistic and
encouraging attitude.

In the end I would like to thank the ESCORTS AGRI MACHINERY

GROUP for providing me with this brilliant opportunity to understand
the working of an industry and developing my technical aptitude.
 PREFACE

Industrial training now a day’s one & the only one method to make
students familiar with the modern techniques, latest equipments &
methods used in various industries. During industrial training, students
visit to various companies and make themselves familiar with the
practical aspect of the production method.

This training has provided and ultimate experience& opportunity to have

practical knowledge which has increased my level of thinking and
dealing with different kinds of people in all walks of life. It helps us a lot
while appearing to the interviews. Industrial training in proves the
theoretical and the practical concept of the student about engineering.

The well planned, properly executed & evaluated industrial training

helps a lot in inculcating good work culture. It provides linkage between
the students & the industries in order to develop and awareness of
industrial approach to problem solving based on broad understanding of
plant.
 THE SYMBOL OF ESCORTS

ESCORTS symbol holds more than meets the eye graphically.

It has been prepared with certain objective in mind & symbolic in

more than one way.

The philosophy behind ESCORTS & ESCORTS symbol is an

enterprise.

The hexagon is a symbol of precision when interpreted as a nut; it

symbolizes craftsmanship & unending productivity. The spanner
superimposed the hexagon represent the work and the people of
ESCORTS. This forms the letter “E” the letter ESCORTS an ever on the
move changing invading the future.

E - ENSURE INBUILT QUALITY

S - SAVING ENERGY
C - CALTIVATE SAFE HABITS
O - OBSERVE PROCESS NORMS
R - REDUCE WASTAGE
T - TAKE CARE OF MACHINE
S - STRIVE FOR EXCELLENCE
They hopes, aspirations, teamwork and sense of communication help
ESCORTS to achieve what it is today, a good reason to work harder or a
still better tomorrow.
ESCORTS PROFILE
Escorts came into being with a vision that was nurtured by MR. HARI
NANDA and Late MR. YUDI NANDA.

The foundation of ESCORTS Limited was laid in the formation of

ESCORTS (agents) Ltd. On 17th October 1944 and of ESCORTS
(Agriculture and machines) Ltd. in 1948. These two were later merged
in 1953 to form ESCORTS Agents Pvt. Ltd. The company’s
incorporation in its present name ESCORTS Ltd. was effected on 19 th
January 1960.

Having initially started with a franchise with Westing House domestic

appliance, it has come a long way in manufacturing and marketing a
range of products. It has pioneered farm mechanization in India through
import and distribution of agriculture tractors.

The manufacturing operations commenced in 1954 and since then the

following range of new products has been produced in the country.
YEAR PRODUCT COMPANY LOCATION
DIVISION
1961 Escorts Tractors Escorts Ltd. Faridabad
(Tractor Division)
1962 Railway Couplers Escorts Railway Faridabad
&Shock Absorbers Equipment
Division
1963 Automotive Shock Automotive Faridabad
Absorbers Suspension
Product (Engg.
Division)
1969 Ford Tractors, Now Escorts Tractors Faridabad
manufactured under Ltd.
the name
“FARMTRAC”
1971 Industrial & Escorts Faridabad
Construction Construction &
Equipment Equipment Ltd.
1991 Financial Services Escorts Finance New Delhi
Ltd.
1996 Disengagement of joint Escorts Farmtrac Faridabad
venture With new div.
Holland & launch of
FARMTRAC Tractor
1998 Foundation of Tractor Carraro India Ltd. Pune
Transmission
Plant(J.V. Carraro Grp,
Italy)
1998 Foundation of 3rd Escorts Ltd. Pune
Tractor Plant
 INTRODUCTION
In today’s competitive world with fast depleting material resource, and
with all its limitations, it has become imperative to develop human
resources and its effectiveness. The continued effectiveness and
efficiency of an organization to some extent depend on the ability of its
employees to produce at high levels of efficiency, and to keep abreast
with role, which the job demands. Training should be a long terms
investment in human resources which can be achieved by following the
equation.

Performance = Ability * Efficiency

Training can have an impact of both these factors. It is a powerful tool

that can have a major impact on the employee’s productivity and morale.

The first and foremost activity concerned with this effort is to identify
their training needs. The needs of the employees may very from
department to department, from person to person and from organization
to organization.

The concept aims to meet an employee’s needs/goals with current or

future opportunities with in organization and pertaining to changing
environment of the industry. The activity recognizes the employee’s
needs for advancement in his carrier and of better opportunities to use
his talent.

It appreciates the fact that employees should be trained for new

technology. The organization may move into other areas, changing the
type of skills necessary to do, Training of employees can be a fruitful
means for the organization to increase
its productivity, to sustain the existence of the organization in a better
way and finally, to prepare them for the future.
ESCORTS: RESTRUCTURING

Escorts Limited is all set to face the future by drawing on its 50 years of
experience, its inherent strengths and a strong presence in the core sector
providing complementary product line and a vast marketing network
combining them with India’s intrinsic cost advantages to become a
global source point for high value engineering products.

In order to meet the challenges in the future and to leave an indelible

mark on the industrial scenario, Escorts has restructured the group along
six business lines, each headed by an independent CEO. The business
groups are as follows:-

1. Agri- Machinery Group

2. Construction-Equipment
3. Automotive Ancillaries
4. Financial Services

The flag ship of the ESCORTS group is ESCORTS LTD. In the work of
MR. RAJAN NANDA, Chairman Escorts Ltd.

“In the last 50 years ESCORTS has been more than merely one of the
INDIAS largest engineering companies. It has been a prime mover on
the industrial front, at every stage introducing products & technologies
that helped to take the country forward in key areas. Today as the nation
engages in its most momentous economic transformation ever, we are
once again adapting ourselves towards being catalyst for qualitative
growth by engineering change with a global prospective.”

THIS INFRASTRUCTURE COMPRISES:-

► 23 Main Associates/subsidiary Companies

► 12 manufacturing Locations
► A full-fledged R&D facility
►Nearly 10,000 Employees
►24 Regional marketing offices
► Nearly 500 Sales & Services Outlets
► 4 Financial Services Companies
► Asia’s best training institute of Farm Mechanization with 100 acre
demonstration farm
► Escorts Dealer Development Association (EDDAL) Ltd. providing
Management & Financial supports to dealers.
 AGRI MACHINERY GROUP

Escorts Agri Machinery group is one of the six strategic business units of
Escorts group and the largest contributor to the group turn over. Escorts
initiated its venture tractors with an assembly plant in 1961. The first
agricultural tractors under the brand name of “ESCORTS” were produced
in 1961. Following the collaboration with ford motor company, Escorts
started another brand name to its portfolio – the ford series of tractors in
1969. Following the disengagement agreed with FORD NEW
HOLLAND, Ford was renamed as FARMTRAC in 1966 & was
relaunched in Indian market.

Escorts have made dent in exports as well as tapped the U.S. market in a
significant way. Escorts is acquiring 49% equity in long manufacturing
company based in north Carolina which is currently distributing its
tractor, with over 5 lakhs tractor having been sold by company till date,
every fourth tractor is a tractor from ESCORTS. Technology up
gradation, product improvement, better services, wider distribution
network & capacity expansion is the BUZZWORDS in ESCORTS AMG.

ESCORTS with its two brands of FARMTRAC & ESCORTS

TRACTORS are amongst India’s largest manufacturers of tractors in 25
to 50 HP range. The performance characteristics of ESCORTS AND
FARMTRAC are unmatched

AMG of ESCORTS limited is responsible for the marketing of both

ESCORTS & FARMTRAC brands of tractors. The operational structure
of AMG comprises of 4 regional & 19 area offices and functions on
countrywide scale. Service and part personnel are responsible for
promoting sales, extending services to the customer and ensuring
availability of spare parts. Thus AMG continues to play its productive
role on the farm front by putting more & more tractors at the service of
Indian market.
AGRI MACHINERY GROUP
PRODUCT RANGE:

1. ESCORTS SERIES (ECONOMY RANGE) 27-35 HP

2. POWERTRAC SERIES (VALUE RANGE) 30-47 HP
3. FARMTRSC SERIES (PREMIUM RANGE) 30-75 HP

THE ESCORTS RANGE:

E325 :
27 HP Diesel Engine, 2 cylinders, 6+2 sliding mesh transmission,
shoe brakes, lower link sensing, color-white & auto glow.

E335 :
35 HP Diesel Engine, 2 cylinders, 6+2 sliding mesh transmission,
shoe brakes, lower sensing, color-white & auto glow.

E340 :
40 HP Diesel Engine, 3 cylinders, 6+2 or 10+2 sliding mesh
transmission, dry disc brakes.

THE FARMTRAC RANGE:

FT30 :
 30HP Diesel Engine, 3 cylinder, 6+2 constant mesh transmission,
Dry disc brakes, color-blue

FT35 :
35 HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,
Dry disc brakes, color-blue

FT45 :
42HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,
Dry disc brakes, color-blue

FT50 :
42HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,
shoe brakes, color-blue

FT55 :
47HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,
Dry disc brakes, color-blue

FT60 :
50HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,
Dry disc brakes, color-blue

FT70 :
60HP Diesel Engine, 3 cylinder, 12+12 partially synchroshuttle
transmission, oil immersed brakes, color-blue
 TRACTOR M/C SHOP (PLANT-1)

The various departments of the Tractor Machine Shop Plant-1 are as

follows:

1. Gears and Shafts:

The major components manufactured by Gears and Shafts division are:

►Engine Gears
►Transmission Gears and Shafts
►Differential Gears and Shafts
►Lever

2. Tool Room:

The Tool Room caters to jig, fixtures, dies manufacturing etc.

3. Power house:

The Power House has generators and compressors of varying capacities.

4. Heavy Castings:

The components manufactured by Heavy Castings Division are

►2 Cylinder Engine Block

►3 Cylinder Engine Block
 ►Gear Box Housing
►Differential Housing

Escorts Plant-3 is engaged in assembly of various models of Escorts

Tractors. It has the following shops:

►Engine Assembly Line

►Engine Testing
► Paint Shop
►Transmission Assembly
► Main Assembly
► Rear Line
►Front Line
Our project is concerning about manufacturing SHAFT
HYDRAULIC LIFT ARM (Serration Shaft).

The various processes involved are:-

1) Facing & Centering

2) Rough Turning
3) Finish Turning
4) Drilling
5) Rolling
6) Hobbing
7) Welding
8) Green grinding
9) Induction hardening
10) Tempering
11) Straightening
12) Hard grinding
13) Hand work
14) Inspection
 Facing & Centering
Facing is part of the turning process. It involves moving the cutting tool
at right angles to the axis of rotation of the rotating work piece. This can
be performed by the operation of the cross-slide, if one is fitted, as
distinct from the longitudinal feed (turning). It is frequently the first
operation performed in the production of the work piece, and often the
last- hence the phrase "ending up".
This process is used for reducing length and smoothening the face.

Tooling element :- STD Self Centering Vice

TGR-F-3951 PADS
Swiveling Stopper
Cutting Tool Details :- STD Centre Drill DIA 5/16 inch
STD Face Mill Cutter
Speed :- Centre Drill -1000rpm
Face Mill Cutter -139rpm
Cutting Time :- 1.5 min
Tool Life :- Centre Drill 500 components
Face Mill Cutter 100 components
Gauge Details :- STD Height gauge (0-500)
TGR-G-9120 Centre Depth Checking
Gauge 5.20/5.0
 Rough Turning

When a great deal of stock is to be removed, you should take heavy cuts
to complete the job in
the least possible time. This is called rough turning. Select the proper
tool for taking a heavy chip.
The speed of the work and the amount of feed of the tool should be as
great as the tool will stand.
When you take a roughing cut on steel, cast iron, or any other metal that
has a scale on its surface,be sure to set the tool deep enough to get under
the scale in the first cut. Unless you do, the scaleon the metal will dull or
break the point of the tool.
Rough machine the work to almost the finished size; then take careful
measurements.
Tooling element :- clamping jaws MAS-317/24
Indexing plate MAS-317/9
Tool holder L-170-5-3225
Tool change frequency :- 200 pcs per edge
Feed :- 0.28 mm/rev
Spindle speed :- 800 rpm
Gauge details :- STD SNAP gauge 51.00±0.15
DIAL indicator L.C 0.01
 Finish Turning
When you have rough turned the work to within about 1/32 inch of the
finished size, take a finishing cut. A fine feed, the proper lubricant, and,
above all, a keen-edged tool is necessary to produce a smooth finish.
Measure carefully to be sure you are machining the work to the proper
dimension. Stop the lathe when you take measurements if you must
finish the work to close tolerances, be sure the work is not hot when you
take the finish cut. If you turn the workpiece to exact size when it is hot,
it will be undersize when it has cooled.
Perhaps the most difficult operation in machine work is to make
accurate measurements. So much depends on the accuracy of the work
that you should make every effort to become proficient in the use of
measuring instruments.

Tooling element :- Soft Jaws TGR-F-9114

Cutting Tool Details :- STD T-Max Tool Holder PDJNL-2525

Speed :- 750rpm

Feed :- 0.2mm/min

Cutting Time :- 3.2 min

Tool Life :- 500 components

Gauge Details :- STD SNAP gauge

DIA 59.69/59.45
 Drilling

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole

in solid materials. The drill bit is a multipoint, end cutting tool. It cuts by
applying pressure and rotation to the workpiece, which forms chips at
the cutting edge.

Machine name :- Radial drill machine

Tooling element :- quick change chuck and sleeve
Cutting tool :- HSS drill dia 11.5 mm
Counter drill dia 13 mm
Tap ½ 20 UNF-2B
Reamer Ø 8H11
Cutting speed :- HSS drill 580 rpm
Counter drill 300 rpm
Tap 180 rpm
Reamer 180 rpm
Feed :- HSS drill 0.2mm/rev
Counter drill 0.2mm/rev
Gauge Details :- STD Threading gauge
GO , NO GO for
½ 20 UNF-2B thread
Center distance gauge
FTHL-G-9008
 Hobbing
Hobbing uses a hobbing machine with two non-parallel spindles, one
mounted with a blank workpiece and the other with the hob. The angle
between the hob's spindle and the workpiece's spindle varies, depending
on the type of product being produced. For example, if a spur gear is
being produced, then the hob is angled equal to the helix angle of the
hob; if a helical gear is being produced then the angle must be increase
by the same amount as the helix angle of the helical gear. The two shafts
are rotated at a proportional ratio, which determines the number of teeth
on the blank; for example, if the gear ratio is 40:1 the hob rotates 40
times to each turn of the blank, which produces 40 teeth in the blank.
Note that the previous example only holds true for a single threaded hob;
if the hob has multiple threads then the speed ratio must be multiplied by
the number of threads on the hob. The hob is then fed up into workpiece
until the correct tooth depth is obtained. Finally the hob is fed into the
workpiece parallel to the blank's axis of rotation.
Up to five teeth can be cut into the workpiece at the same
time. Oftentimes multiple gears are cut at the same time.
For larger gears the blank is usually gashed to the rough shape to make
hobbing easier.

Tooling Element :- Job Carrier

Cutting Tool Details :- HOB Cutter
Gauge Details :- OUTSIDE MICROMETER 50-75 mm
L.C- 0.01
DIAL indicator L.C 0.01
CONCENTICIT BENCH
 Rolling

Tooling Element :- STD Collet for clamping

ALT. for Hobbing

Cutting Tool Details :- STD Grob Rool

HOB Cutter

Cutting Time :- 2 min

Gauge Details :- Outside Micrometer 50-75mm

Least count - 0.01mm
FTHL-G-9030
Serration Ring Gauge ”Go”
 Welding

The arc welding makes arcs between a material

and a welding rod. And it is a well used welding
method. In the arc welding, we use a torch with a
welding rod as shown in Figure 1. And both of the
material and the welding rod are meant in the arc.
The arc welding is very high speed, and if the
welding is very well, the strength is very high. But
the arc is very light, then we cannot see the
welding processes.

All weldings, including the arc welding, need

higher technique than cutting processings,
because we do not have the same conditions.

Welding is done on one spline corner on both sides

46 splines
53 splines
 Grinding
Grinding practice is a large and diverse area of toolmaking. It can
produce very fine finishes and very accurate dimensions; yet in mass
production contexts it can also rough out large volumes of metal quite
rapidly. It is usually better suited to the machining of very hard materials
than is "regular" machining (that is, cutting larger chips with cuttin
tools such as tool bits or milling cutters), and until recent decades it was
the only practical way to machine such materials as hardened steels.
Compared to "regular" machining, it is usually better suited to taking
very shallow cuts, such as reducing a shaft's diameter by half a thousand
of an inch (thou).(1 thou == 25 um)
Technically, grinding is a subset of cutting, as grinding is a true metal
cutting process. Each grain of abrasive functions as a microscopic
single-point cutting edge (although of high negative rake angle), and
shears a tiny chip that is analogous to what would conventionally be
called a "cut" chip (turning, milling, drilling, tapping, etc.). However,
among people who work in the machining fields, the term cutting is
often understood to refer to the macroscopic cutting operations,
and grinding is often mentally categorized as a "separate" process. This
is why the terms are usually used in contradistinction in shop-floor
practice, even though technically grinding is a subset of cutting.

Tooling element :- Grinding abrasive wheel

Speed :- 39 and 220 rpm
Cutting tool :- Pneumatic grinder
 Hardening & Tempering

Tempering is a heat treatment technique for metals, alloys and glass.

tempering is done to "toughen" the metal by transforming
brittle martensite or bainite into a combination of ferrite and
cementite. Precipitation hardening alloys, like many grades of aluminum
and superalloys, are tempered to precipitate intermetallic particles which
strengthen the metal. Tempering is accomplished by a controlled
reheating of the work piece to a temperature below its lower critical
temperature.
The brittle martensite becomes tough and ductile after it is tempered.
Carbon atoms were trapped in the austenite when it was rapidly cooled,
typically by oil or water quenching, forming the martensite. The
martensite becomes strong after being tempered because when reheated,
the microstructure can rearrange and the carbon atoms can diffuse out of
the distorted body-centred-tetragonal (BCT) structure. After the carbon
diffuses, the result is nearly pure ferrite with body-centred structure.
In metallurgy, there is always a trade-off between strength and ductility.
Precise control of time and temperature during the tempering process are
critical to achieve a metal with well balanced mechanical properties.

Power :- 220-244 V
Pre-Heating Time :- 1.4 sec
Feed Rate :- 9mm/sec (53 spline gauge)
Quench dwell time :- 32 sec
Speed :- 80 rpm
 Inspection

INSPECTION IS THE LAST STAGE OF MANUFACTURING.IT IS

DONE MANUALLY TO CHECK FOR DEFECTS AND OTHER
IRREGULARITIES.

Gauge details :- SERRATION RING GAUGE

FTHL-G-9030 ‘GO’
SERRATION RING GAUGE
FTHL-G-9031 ‘NO GO’
ON MATERIAL 6 SPLINE