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FROM 14/5/09 TO 16/5/09
STAGE 1&2: Already assembled FR Axle & Rear axles from machine shop-4 are fixed on the main frame that fabricated from the machine shop 3 of the vehicle. STAGE 3: The fixed frame assembly is placed on the conveyor belt, where brake chamber is fitted to it. STAGE 4: Steering gear box is fitted to the main frame. STAGE 5: Silencer tank is fixed to the main frame. STAGE 6: Then fuel tank is fitted in this stage of chassis assembly. STAGE 7: Engine mounted on the main frame of the chassis of the vehicle. STAGE 8: Radiator fixed in front of the engine. STAGE 9: Tyres for all the wheels are fixed to the drums of the axles. STAGE 10: The vehicle is toed then and taken to the other unit to make it running conditions and test driven.
STAGE 10: PISTON The readily made piston is fixed inside bore of the crankcase and connected to thecrankshaft. Before that. . STAGE 5: TIMING BRAKE PLATE In this stage 1st and 6th piston is kept at the top dead centre and timing gears are fixed to side of the engine for the firing order. STAGE 4: M-14 STUDS are fixed at the holes on the crankcase. crank gear and compressor gear. STAGE 6: CAM GEAR Cam gears are fixed on the crankcase to operate the cam shafts in order to operate the valves. flange and flywheel. piston rings of three types. STAGE 7: FLYWHEEL housing is fixed on the crankcase of the engine. STAGE 3: CRANK SHAFT Crank shaft. STAGE 11: CONROD BOLT Conrod bolt is fixed to connect the piston with the crank shaft. STAGE 2: CAM SHAFT Cam shaft types E0/EI/EII NO are fixed in appropriate place in the crankcase. make BM/GB is fixed at base of crank case like passing thru hole. two compression rings and an oil ring are fixed on the piston. The flywheel housing consists of seal housing. STAGE 9: OIL PUMP Oil pump is fixed on the top of the crankcase to circulate the oil to the various parts of the engine. STAGE 12: IDILING GEAR: It s fixed on the spindle which controls the rotations of cam gear.ENGINE ASSEMBLY: FROM 19/5/09 TO20/5/09 STAGE 1: CAM BEARING Crank case SWR/plate/EII NO is brought to the engine assembly. STAGE 8: The flywheel is placed on the housing and 90torques is applied to it. here cam bearings are fixed to the crank case of the engine.
MACHINE SHOP-2: FROM 21/05/09 TO 22/05/09 Here in this shop the perfectly casted part of crankcase arrives from the casting plant situated somewhere near the main plant. STAGE 14: OIL SUMP Oil pump is fixed at the bottom of the crankcase with adhesive (RTV) paste. STAGE 21: SIDE COVER STAGE 22: WATER PUMP STAGE 23: STARTER MOTOR STAGE 24: EXHAUST MANIFOLD STAGE 25: TURBO CHARGER STAGE 26: EII FTMENTS STAGE 27: Fully assembled is taken to the testing area to be tested for is performance. STAGE 15: ROCKER Rocker assembly is fixed to the cylinder head. There are different process of manufacturing is done here.STAGE 13: CYLINDER HEAD: Cylinder head is fixed to the top of the crankcase to which rocker arm with valves are fixed. STAGE 17: FUEL INJECTION PUMP Fuel pump is fixed to LTC/EII/EI types of engines. STAGE 18: VALVE COVER STAGE 19: OIL COOLER STAGE 20: INJECTOR PIPE AND INLET MANI FOLD is fitted. STAGE 16: AIR COMPRESSOR AIR COMPRESSOR is fixed to the crank case. . This shop-2 consist of the heavy machines of HMT that helps in boring and drilling different sizes of holes needed for the fitments of various engine spares. This casted crankcase constitutes the main part of the engine compartment.
STAGE 2: Number is punched on the axle beam. STAGE 4: Ring for oil seal is fitted on the hub shim is fitted 3-6tau for the clearance flange cover is fitted with 4 bolts. The frames of the vehicles are fixed together to be sent to the chassis assembly. STAGE 3: Brake nut and bolt are tighten and fitted 75 to 50 torques. where the wheel hub is fixed roughly to verify whether to increase or decrease the shim. MACHINE SHOP -4: FROM 27/05/09 TO 28/05/09 This shop-4 is divided into two departments where the front and rear axles of the vehicles are assembled with leaf springs.MACHINE SHOP-3 26/05/09 The chassis of the vehicle first step starts from here at this shop-3. On the rear end of the frame BKTS both sides are aligned with taper pin. The skids are mounted on the conveyor belt and frame is placed on the skids. STAGE 3: Axle arm is fitted on the beam for steering. Tilt both the FSMS to 90 degree by turning tackle and insert clamps. . Tight and apply torque to engine MTG flinches and M12 with bolts. Dust cover is also fitted. It helps the left side of the tyre to turn along with the right side wheel. brake drums before being attached to the main frame of the vehicle. Correspondingly in every stage each workers tight appropriate bolt to the frame before taken to chassis assembly make it a complete frame. Firstly Front axle assembly: STAGE 1: Axle beam is loaded on the conveyor belt. STAGE 5: Tracking rod is fitted. REAR AXLE ASSEMBLY: STAGE 1: Banjo casing from outside is unloaded and fixed on the conveyor and axle shaft is removed. It is used for the alignment of the wheel. STAGE 2: Brake lining and 10 bolt and washer are fixed on the brake carrier with spring washer. Fit and tight FSR and BKTS on both sides with dummy bolts. STAGE 7: Dry set. And frame MTG on which engine is mounted is fixed across the two frames. STAGE 5: Inner oil seal is fitted on ring for inner oil seal. STAGE 4: Steering rod is fitted. STAGE 6: Brake carriers with brake linings are fitted to the FR axle beam and taken to chassis assembled. Inner wheel bearing is fitted. STAGE 6: Distance piece is fixed to align the inner and outer wheel bearing in the same axis. It is right end of the axle according to Indian STDs.
STAGE 11: Axle shaft is fitted using 8 spring washer and nut on the stud. . studs are fixed in the hub to fixed to the shaft. Grease nipple is fixed on the wheel hub. CONCLUSION: It s been privilege to do in plant training in one of the India s largest automobile producer ASHOK LEYLAND.STAGE 8: WET SET Where grease is packed inside the wheel hub. STAGE 10: Axle studs are tightened to 50-60 taus. It has helped in many ways to improve the knowledge about the actual work done in the industries and to have hands on experience. The given. 190 tau tightness. STAGE 12: Complete assembly of rear axle is unloaded and taken to chassis assembly. STAGE 9: Axle tube nut is fixed with counter pin and bolt. Drum is fixed 8mm bolt is fitted.
Today the company is the flagship of the Hinduja Group. and continued in production for many years. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment with a market share of 28% (2007 08). India. more people than the entire Indian rail network.000 engines annually. The origin of Ashok Leyland can be traced to the urge for self-reliance. India s first Prime Minister. It sells about 60. and over 8.680 engine. but was restarted by Ashok Leyland in India. Travancore State Transport.000 vehicles and about 7. the Comet was operated by every State Transport Undertaking in India. an industrialist. to enter automotive manufacture.Early products includedthe Leyland Comet bus which was a passanger body built on a truck chassis. With passenger transportation options ranging from 19 seaters to 80 seaters.000 were in service. The Ashok Leyland Titan was very successful. . The Comet was soon joined in production by a version of the Leyland Tiger.5 tons). a British-based and Indian originated transnational conglomerate. Ashok Leyland vehicles have built a reputation for reliability and ruggedness. Ashok Leyland is a market leader in the bus segment. felt by independent India. the company is one of India's leading manufacturers of commercial vehicles. Pandit Jawaharlal Nehru. including Hyderabad Road Transport. to assemble Austin cars. Operating six plants. Founded in 1948. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. The company claims to carry over 60 million passengers a day. BSE: 500477) is a commercial vehicle manufacturing company based in Chennai.INTRODUCTION: Ashok Leyland (NSE: ASHOKLEY.5 tons to 49 tons. However Ashok Leyland has presence in the entire truck range starting from 7. And this is the report of In plant training done in this well reputed organization for period of two weeks. Ahmedabad Municipality. Ashok Leyland also makes spare parts and engines for industrial and marine applications. By 1963. such as trucks and buses. persuaded Mr Raghunandan Saran. In 1968. The joint venture announced with Nissan Motors of Japan would improve its presence in the Light Commercial Vehicle (LCV) segment (<7. together with the Ashok Leyland version of the O. This was mainly due to the product design legacy carried over from British Leyland. The company s destiny and name changed soon with equity participation by British Leyland and Ashok Leyland commenced manufacture of commercial vehicles in 1955. The company was established in 1948 as Ashok Motors. and a five speed heavy duty constant-mesh gearbox utilized. production of the Leyland Titan ceased in Britain. as well as emergency and military vehicles.Over the years. Bombay State Transport and Delhi Road Transport Authority. sold in large numbers to many operators. The Titan PD3 chassis was modified.
ENNORE BETWEEN 14/05/09 AND 28/05/09 K.BALAKUMARAN B.TECH (MECHANICAL) FINAL YEAR -07BME058 VIT UNIVERSITY VELLORE .REPORT OF IN-PLANT TRAINING UNDERGONE IN ASHOK LEYLAND.