ESCORTS AGRI MACHINERY GROUP

INDUSTRIAL PROJECT REPORT

SUBMITTED BY:
NAME:- shaleen
ROLL NO:- 1149240091
COLLEGE:- KCC INSTITUTE OF TECHNLOGY
AND MANAGEMENT
BRANCH:- MECHANICAL ENGINEERING

ESCORTS AGRI MACHINERY GROUP

INDUSTRIAL PROJECT REPORT

ESCORTS AGRI MACHINERY GROUP

INDUSTRIAL PROJECT REPORT

ACKNOWLEDGMENT
PREFACE
THE SYMBOL OF ESCORT
ESCORTS PROFILE
INTRODUCTION
ESCORTS:RESTRUCTURING
AGRI-MACHINERY GROUP
TRACTOR M/C SHOP(PLANT 1)
SHAFT HYDRAULIC LIFT ARM
FACING AND TURNING
ROUGH TURNING
FINISH TURNING
DRILLING
HOBBING
ROLLING
WELDING
GRINDING
HARDENING AND TEMPERING
INSPECTION

CONTENTS

ACKNOWLEDGEMENT
I would like to thank to all those with whom I worked and whose thoughts and
insights helped me in increasingmy knowledge and understanding of working in
the organization .
I would like to pay my sincere gratitude to MR. RAJENDRAYADAV & all employees, my project guide, who
helped me during the course ofmy training by providing his valuable suggestion, ideas and guidance
which proved beneficial for completion ofmy 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 theproject.

These people made me comfortable tounderstand the functioning ofeach machine

& aboutthe 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 neverhave taken its present form. In
fact this project is the resultof their vision, optimistic and encouraging attitude .

In the end I would like to thankthe ESCORTS AGRI MACHINERYGROUP for providing
me with this brilliant opportunity to understand the working of an industry and
developing my technical aptitude

PREFACE
Industrial training now a days one & the onlyone method to make
students familiar with the modern techniques, latest equipments &methods used in
various industries. During industrial training , students visit to various companies
andmake themselves familiar with the practical aspect ofthe production method .

This training has provided and ultimate experience&opportunity to have practical

knowledge which has increased my levelof 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
ofthe student about engineering.

The well planned, properly executed & evaluatedindustrial training helps a lot in inculcating
good workculture. It provides linkage between the students & the industries in orderto
develop and awareness of industrial approach toproblem 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
thepeople of
ESCORTS. This forms the letter E theletter 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 senseof 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 ofESCORTS (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 companys
incorporation in its present name ESCORTS Ltd. was effected on 19th January 1960.

Having initially started with a franchise withWesting House domestic appliance, it has
come a long way in manufacturing and marketing arrange 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 productshas been produced in the country.

YEAR
1961

1962
1963

PRODUCT
Escorts Tractors
Railway Couplers & Shock
Absorbers
Automotive Shock
Absorbers

1969
Ford Tractors, Now
manufactured under the
FARMTRAC

COMPANY
DIVISION
Escorts ltd. (Tractor
Division)
Escorts Railway
Equipments Division
Automotive
Suspension Product
(Engg. Division)

LOCATION
Faridabad
Faridabad
Faridabad
Faridabad

Escorts Tractors Ltd.

1971
Industrial & Construction
Equipment
1991
Financial Services
1996
1998
1998

Disengagement of joint
venture with new Holland
& launch of FARMTRAC
Tractor
Foundation of Tractor
Transmission Plant (J.V. ca
rraro Grp, Italy)
Foundation of 3rd Tractor
plant

Faridabad
Escorts Construction
& Equipment Ltd.
Faridabad
Escorts Finance Ltd.
Faridabad
Escorts Farmtrac div.
Faridabad
Carraro India Ltd.
Escorts ltd.

Pune

INTRODUCTION
In todays competitive world with fast depleting material resource, and with all its limitations, ithas
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 a breast 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 apowerful tool that can have amajor impact on
the employees 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 anemployees needs/goals with current or future opportunities with in
organization and pertaining to changing environment of the industry. Theactivity recognizes the
employees 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 theorganization to increase its productivity, to sustain the existence ofthe 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
vastmarketing network combining them with Indias intrinsic costadvantages 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 headedby an independent CEO. The business groups are as follows:-

1.Agri- Machinery Group

2.2. Construction-Equipment
3.3. Automotive Ancillaries
4.Financial Services
The flag ship of the ESCORTS group is ESCORTSLTD. In the workof MR. RAJAN NANDA, Chairman Escorts Ltd.

In the last 50years ESCORTS has been more than merely one ofthe INDIAS largest engineering
companies. It has been a prime mover on the industrial front, at every stageintroducing products
&technologies that helped to take the country forward inkey areas. Today as the nation engages
inits most momentous economic transformation ever, we areonce 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

Asias 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 turnover. Escorts initiated its venture tractors with an assembly plant in1961. 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 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 iscurrently distributing its tractor,
with over 5lakhs 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 BUZZ WORDS in ESCORTS AMG.

ESCORTS with its two brands of FARMTRAC & ESCORTSTRACTORS are amongst Indias largestmanufacturers of
tractors in25 to 50 HP range. The performance characteristics of ESCORTSAND FARMTRAC are un matched 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 partpersonnel are responsible for promoting sales, extending services tothe customer and
ensuring availability of spare parts.Thus AMG continues to playits productive role on the farm front by putting
more &more tractors at the service of Indian market.

AGRI MACHINERY GROUPPRODUCT

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 meshtransmission, dry disc brakes .

THE FARMTRAC RANGE:

FT30 :

30HP Diesel Engine, 3 cylinder, 6+2 constant mesh transmission, Drydisc brakes, color-blue

FT35 :
35 HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission,Dry disc brakes, colorblue
FT45 :
42HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission, Drydisc brakes, colorblue
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, Drydisc brakes, colorblue
FT60 :
50HP Diesel Engine, 3 cylinder, 8+2 constant mesh transmission, Drydisc brakes, colorblue
FT70 :
60HP Diesel Engine, 3 cylinder, 12+12partially synchroshuttletransmission, oil immersed
brakes, color-blue

TRACTOR M/C SHOP (PLANT1)

The various departments of the Tractor Machine Shop Plant-1 areas 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 ViceTGR-F-3951 PADS
Swiveling Stopper
Cutting Tool Details :-STD Centre Drill DIA 5/16 inch STD Face Mill Cutter
Speed :-Centre Drill -1000rpmFace Mill Cutter -139rpm
Cutting Time:- 1.5 min
Tool Life:- Centre Drill 500componentsFace 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 ofthe 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 setthe tool deep enough to get under the scale in the
first cut. Unless you do, the scale on 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 51.000.15
DIAL indicator L.C 0.01

Finish Turning
When you have rough turned thework to within about 1/32 inch ofthe 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 work piece 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 orenlarge a hole in solid
materials. The drill bit is a multipoint, end cutting tool. It cuts by applying pressure and
rotation tothe work piece, 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 20 UNF-2B
Reamer H11
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 20 UNF-2Bthread
Center distance gauge
FTHL-G-9008

Hobbing
Hobbing uses a hobbing machine with two non-parallel spindles, one mounted with a blank work piece and
theother with the hob. The angle between the hob's spindle and thework piece's spindle varies ,depending on
the type of product beingproduced. 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 ofthe 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 ofthe blank, which produces 40 teeth in theblank. Note that the previous example only holds true
for a single threaded hob; if the hob hasmultiple threads then the speed ratio must be multiplied by the
number of threads on the hob. The hob is then fed up into work piece until the correct tooth depth is obtained.
Finally the hob isfed 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
.

ToolingElement:-Job Carrier
CuttingToolDetails:-HOB Cutter
Gauge Details:-OUTSIDEMICROMETER50-75mm
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. 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, needhigher technique than
cutting processings, because we donot have the same conditions.

Grinding
Grinding practice is a large and diverse area of tool making. It can produce very fine finishes and very
accurate dimensions; yet in mass production contexts it can also rough outlarge 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 isusually 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 chipthat 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
termcuttingIs oftenunderstood to refer tothe macroscopic cutting operations, andgrindingis 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 asubset of cutting .

Toolingelement
Speed
Cuttingtool

:::-

Grinding abrasive wheel

39 and 220 rpm
Pneumatic grinder

Hardening & Tempering

Tempering is a heat treatment technique for metals, alloys and glass. tempering is done to "toughen" the metalby transforming
brittle martensite or bainite into acombination of ferrite and cementite. Precipitation hardening alloys, like many grades
ofaluminium and super alloys, are tempered to precipitate inter metallic 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 afterbeing tempered
because when reheated, the microstructure can rearrange and the carbon atoms can diffuse out of the distorted body-centredtetragonal (BCT) structure. After the carbon diffuses, the result isnearly pure ferrite with body-centred structure.
In metallurgy, there is always a trade-offbetween strength and ductility. Precise control of time andtemperature during the
tempering process are critical toachieve 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 OFMANUFACTURING.ITIS DONE MANUALLY TO CHECK FOR
DEFECTS AND OTHERIRREGULARITIES.

Gaugedetails
GAUGE

:-

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

SPLINE