Crank case manufacturing at pritika industries

Crank Case manufacturing at pritika industries, mohali. it also contains the time study project.

1. Six week industrial training at Pritika industries limited Submitted by : Jagmohan Dhiman (2312625) Naval Gupta (2312642) Submitted To :

2. Pritika at a Glance Pritika started in 1974 by Mr. R.S.Nibber , a young technocrat, manufacturing small automotive components. The company’s products include machine components, heavy castings, flywheel housing, crank case and hydraulic lift cover. The quality driven organisation "PRITIKA Group of Industries" is producing world class components from modern facilities.

3. Products at Pritika It is the leading supplier & manufacturer of housings and casting components. Most of the components which are manufactured at pritika are made of Cast iron because it has ultimate compressive strength and provide strength to the component.

4. It is the leading supplier of Hydraulic lift cover and the engine covers. The Crank Case manufactured here is supplied to mahindra tractors. And the other casting components are supplied to various renowned companies.

5. Crank Case In an internal combustion engine of a reciprocating type, the crank case is the housing for the crank shaft. A crank case is made up of Cast iron via sand casting. Besides protecting the crankshaft and connecting rods from foreign objects, the crankcase serves other functions. It include keeping the motor oil contained, providing the rigid structure to the engine for transmission.

6. Flow Chart Storage & inspection of cast material Dowel Hole Drilling Pre- machining ( top & side faces ) Final milling ( top & side faces) Multiple operation on VMC Crank side boring Cam bore Gang milling I.G. bore Final inspection Transportation

7. Process 1 – Radial Drilling Here in this first process, the dowel hole drilling is done. These are the holes which will help the crank case to be clamped in further machines. The one and only purpose of drilling these holes is to mark those areas where clamps are fitted and there will be no wrong clamping. Dimensions of holes drilled here: Drill diameter - 14.5 mm Drill depth - 21 mm Reamer diameter - 15 mm

8. Process 2 - Rough Milling This is the process done in two stages. The first machine is machining on top & bottom faces and other is on side faces. The name of machine is Duplex milling machine as the machining is being done on two faces simultaneously. Cutter diameter - 400 mm Feed - 3 mm/min

9. Process 3 - Final Milling Here the machine is again Duplex Milling Machine. As the process is final, so, the accuracy of the machine matters here. This process is also done on two stages. The machine is driven by two powerful motors. Cutter diameter - 400 mm Speed - 500 r.p.m . Feed - 0.2 mm/min

10. Process 4 - Vertical Machining Various processes are being done here which includes : Milling, Drilling, Boring, Tapping on top side of the Crank Case. This machine is popularly known as V.M.C. i.e. Vertical Machining Centre. It is a completely automatic machine in which our work piece is fixed and tool rotates and moves.

11. The various operations performed in V.M.C. are as follows : Boring : Diameter of boring bar - 123.2 mm Speed - 400 rpm Feed Rate - 0.2 mm/min Drilling : Diameter of drill - 31 mm Speed - 650 rpm Milling : Diameter of cutter - 100 mm Drilling : Diameter of bit - 10.2 mm Speed - 1000 rpm Tapping : Diameter of tapp - 12 mm Speed - 500 rpm Feed rate - 0.2 mm/min

12. Process 5-Boring (Crank Shaft) Boring is a process of enlarging a hole that already exists . Boring is done to achieve greater accuracy of the diameter of a hole. The machine used is Dowel Head Boring Machine. Diameter of boring bar - 72 mm Speed - 400 – 650 rpm

13. Process 6 - Boring(Cam Shaft) The bore for Cam Shaft is done here and the machine used is same Dowel Head Boring Machine. The machining of the component is done on both sides simultaneously. So, the rate is quite good and efficient. Diameter of bore - 49 mm

14. Process 7 – Milling The machine name is Gang Milling Machine. As the name suggests Gang + Milling denotes a group of milling cutters mounted on the same arbor in a horizontal milling set up. All the cutters may perform same type of operations. Cutter diameter - 200 mm Speed - 400 – 600 rpm Feed rate - 0.2 mm/min

15. Time Study for Crank Case The time observed for operation on different machines during manufacturing of the Crank Case . A study has been done to calculate the time consumed by the Crank Case for its machining is as follows : Avg. time for R.D.-20 - 8.04 min Avg. time for D.M.M. (pre milling) - 8.26 + 9.55 = 18.35 min Avg. time for D.M.M. (final milling) – 10.54 + 8.30 = 19.4min Avg. time for V.M.C.- 08 - 15.52 min Avg. time for D.H.B.M.- 03 - 6.27 min Avg. time for D.H.B.M.- 02 - 8.28 min Avg. time for Gang Milling - 6.50 min Avg. time for Radial Drill - 1.16 min

16. So, the total average item taken by all the machines = Time taken to manufacture a Crank Case after casting is 8.04 + 8.26 + 9.55 + 10.54 + 8.30 + 15.52 + 6.27 + 8.28 + 6.50 + 1.16 = 84.42 minutes. Hence from the above time study, we have concluded that, A Crank Case takes 1 hr 24 min for its complete production process after casting.