I

II

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

Besides I would also thank to all the supervisors, Foreman and workers who
helped me to understand the depth of my training, what they want out of the
project. These people made me comfortable to understand the functioning of each
machine & about the operation occurring 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 training would never
have taken its present form. Lastly, but not least I thank one and all who have
helped me directly or indirectly in completion of the report.

I have been really opportunistic to be a part of the Escort Group during my summer
training, which is one of the leading tractor company in today’s scenario.

I am once again, thankful to members of ESCORTS Group for their co-operation.

 III

Abstract

Practical training is a way to implement theoretical knowledge to practical use. To

become a successful engineer it is necessary to have a sound practical knowledge
because it is only way by which one can acquire proficiency & skill to work
successfully in different industries.

It is proven fact that bookish knowledge is not sufficient because things are not as
ideal in practical field as they should be.

Escorts Ltd. is one of the best examples to understand the production process and
productivity in particular of Tractor and its parts.

This report is an attempt made to study the overall processes KMC, Assembly
plant and Cylinder block machining. This report presents the Escorts Ltd’s
introduction, technical collaboration, Products. This report also reflects the brief
introduction of Engine and Tractor testing and metrology lab. This is also includes
Assembly Line of Farmtrac Tractor.

Machine shop is the focused part as it was the department allotted to me in Escorts
agri machinary group. The machining processes of cylinder block is carried out at
line E4.286 like facing, drilling, boring, gallarying, turning, finishing etc. The
process in layout of line E4.286 is studied by me during 45 days summer internship
are mostly emphasized within this report.
 IV

Content

Certificate IV
Acknowledgement II
Abstract III
List of Figures IV
List of Tables IV
List of Abbreviation IVI

Sr. No Chapter name Page no

1. Introduction 1
1.1 About escorts Ltd
1.2 Mission
1.3 Quality policy
1.4 Hystory
1.5 Logo
1.6 Key persons
2. Agri machinery Group 7
2.1 Features of AMG
2.2 Turn over
2.3 Product
2.4 Awards
3. KMC 10
3.1Design
3.2 Testing
3.3 Metrology
4. Assembly Plant 16
4.1 Assembly Layout
4.2 Real assembly
4.3 Transmission Assembly
4.4 Assembly of Engine and Clutch Mechanism
4.5 Front axle and accessories and paint
4.6 Rear and Front wheel fitting
4.7 Final Testing
5. Steady of Cylinder Block Machining 25
 V

6. Bolt Selection and Failure 32

6.1 Bolt Grading
6.2 How do you tighten a bolt?
6.3 Torque Specifications
6.4 ISO Standard of bolts
6.5Bolt Failure
7. Conclusion 47
 VI

List of figures

Sr No Fig No Figure Name Page

3.1a &b Real axle and differential 11

3.2 Engine 11
3.3 Test trac 13
3.4 Trimos Height measuring system 15
4.1 Assembly layout 18
4.2 Clutch and break pedal fitting 20
4.3 Engine and fuel tank 20
4.4 Front axle fitment 21
4.5 Painted body of tractor 22
4.6 Rear wheel fitting 23
4.7 Fitment of radiator 24
5.1 Cylinder block 25
6.1 Torque distribution chart 33
6.2 Bolt View 40
6.3 Failure as a result of an overload 43
6.4 Failure due to lack of locking mechanism 44
6.5 Failure from improper torque 45
6.6 Failure from improper manufacture 46
 VII

List of Tables

Table No Name Page

Table 2.1 Products list 8
Table 5.1 Hole dimension 28
Table 6.1 Bolt grade and there 33
material
Table 6.2 Torque requirement 38
Table 6.3 Bolt ISO standard 41
 VIII

List of abbreviations

AMG-Agri machinery group

KMC-Knowledge Management centre

HSS-High speed steel

BSM- Block straight milling

HMC- Horizontal Milling Centre

BNR- Block Nut Turner

VMC- Vertical Milling Centre

BSB- Block straight Boring

BWT- Block Washing Machine

BBP-Block Bush Pressing

PTO-Power take off

FTP-Full throttle performance

TGS-Time gear side

TCS-Tappet cover side

BHS-Bell housing side

NPS- Name plate side

 1

Chapter-1

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.

1.1About The Escorts Ltd.

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

1.2 Mission
“Escorts Endeavour’s to transform lives in rural and urban India by leading the
revolution in agricultural mechanization, modernization of automotive and railway
technology, as well as transformation of Indian construction industry”

1.3 Quality Policy

 2

We shall strive to continuously improve to meet the ever – rising

expectation of our customers at the lower cost. Each one of us must fulfill the need
of our customer, both internal and external with the highest degree of commitment
thereby creating a quality organization geared to ensure total customer
satisfaction and the sustained health and prosperity of our business.

1.4 Company History

The genesis of Escorts goes back to 1944 when two brothers, Mr.
H. P. Nanda and Mr. Yudi Nanda, launched a small agency house, Escorts Agents
Ltd. in Lahore. Over the years, Escorts has surged ahead and evolved into one of
India's largest conglomerates. In this journey of six decades, Escorts has had the
privilege of being associated with some of the world leaders in the engineering
manufacturing space like Minneapolis Moline, Massey Ferguson, Goetze, Mahle,
URSUS, CEKOP, Ford Motor Company, J C Bamford Excavators, Yamaha, Claas,
Carraro, Lucky Goldstar, First Pacific Company, Hughes Communications,
Jeumont Schneider, Dynapac .These valued relationships be it technological or
marketing, are our highly cherished experiences treasures, which have helped us
inculcate best in class manufacturing practices and to emerge as a technologically
independent world class engineering organization.

1944 - Launch of Escorts (Agents) Ltd.

1948 - Pioneered farm mechanization in the country by launching Escorts
Agricultural Machines Limited, with a franchise from the U.S. based Minneapolis
Moline, for marketing tractors, implements, engines & other farm equipment.
Launch of Escorts (Agriculture and Machines) Ltd.1949 - Franchise of Massey
Ferguson tractors for northern India.
1951 - Escorts established India's first private Institute of Farm Mechanization at
Delhi.
1953 - Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged
to form Escorts Agents Pvt. Ltd.
1954 - 1st industrial venture of Escorts to manufacture piston rings in collaboration
with Goetze of Germany, in an era when joint ventures of Indian firms with foreign
companies were virtually unheard of.
1958 - Started importing Massey Ferguson tractors from Yugoslavia for marketing
the same in India.
 3

1959 - Collaboration with Mahle of Germany to manufacture pistons. Soon,

Escorts became the largest producer of piston assemblies in India.
1960 - Set up of Escorts Limited
1961 - Setting up of manufacturing base at Faridabad for manufacture of tractors in
collaboration with URSUS of Poland and 50% indigenous components. Launch of
Escort brand of tractors collaboration with CEKOP of Poland for manufacture of
motorcycles and scooters. Escorts moves into high gear by nurturing the two
wheeler culture. The first Rajdoot motorcycle rolls off the assembly line.

1969 - Escorts Tractors Limited was born a technical and financial joint venture
with the global giant Ford Motor Company, USA, to manufacture Ford tractors in
India. The years ahead saw Escorts grow as the largest tractor manufacturer in
India.
Escorts Institute of Farm Mechanization (EIFM) established at Bangalore.
Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial
democracy comes into being.
1971- 1st February, the first tractor FORD 3000 rolled out of the factory. Escorts
diversifies and starts manufacturing construction equipment.
1974 - Crossing national boundaries, Escorts exports for the first time. After
winning a global tender, 400 tractors were exported to Afghanistan, which was
perhaps the world's largest ever airlift of tractors.
1977 - Escorts enters the world of self-developed technology by setting up its first
independent R&D Center. Escorts Scientific Research Centre marked its beginning
at Faridabad by developing its own Engines for E-27 and E-37. Due to constant
technology absorption, indigenization level touched 72% for FORD tractors. 2nd
plant at Bangalore for manufacturing piston assemblies was set up.
1979 - Collaboration with JCB Excavators Ltd., UK for manufacture of excavators.
1980 - Foray into healthcare, Escorts Hospital and Research Center set up in
Faridabad.
1983 - Escorts Tractors Limited (ETL) established a state-of-the-art research and
development centre to spearhead newer breakthroughs in Farm Mechanisation and
to maintain industry leadership. Line concept introduced for engine block
machining. 11,000 ton floating dry-dock Escorts I launched.
1984 - JV Escorts - Yamaha to manufacture motorcycles.
 4

1984 - Signing of agreement with the Japanese bike giant Yamaha to manufacture
motorcycles with Yamaha technology. Collaboration with Jeumont Schneider of
France to manufacture EPABX systems Collaboration with Dynapac of Sweden to
manufacture vibratory road compactors.
1988 - Escorts Heart Institute and Research Centre (EHIRC), a world class cardiac
care facility launched in New Delhi.
1989 - Joint Venture with Claas of Germany to manufacture harvester combines.
1990-91 - First Public Issue in February 1991, over-subscribed four times. Shares
listed on Delhi and Bombay Stock Exchanges.
1993 - FORD 3620 tractor launched.
1996 - Disengagement of joint venture collaboration with New Holland and launch
of FARMTRAC Tractor.
1997 - Joint Venture with Carraro of Italy for manufacturing and marketing of
transmission and axles. Joint Venture with First Pacific Company of Hong Kong -
Escotel Mobile Communications.
1998 - POWERTRAC series of tractors launched. MoU was signed with Long
Manufacturing Company, USA for setting up a Joint Venture in USA.
1999 - MoU for Joint Venture with a Polish Company POL-MOT was signed for
assembly, manufacturing and marketing of Farm Machinery.
2004 - Divested Escotel Mobile Telecommunications to Idea Cellular
TS16949 certification for Agri Machinery Group.
2005 – Divested Escorts Heart Institute and Research Centre (EHIRC) to Fortis
Healthcare.
2006 - Divested in Carraro India Ltd.
2008 - ECEL launches Fully Hydraulic Crawler Cranes
2009 - ECEL has recently commissioned its state-of-art manufacturing plantrolling
out pick-n-carry cranes and vibratory compactors.

1.5 Company Logo

 5

A hexagonal nut (in red) representing a geometric perfection. The nut has been a
functional device that has stayed at the core of mankind’s engineering adventures.
In spite of modern technologies coming in, it still remains unarguably a symbol of
technology and all that holds it together. Locked into the nut is a spanner (in
white), the turning force for the symbol of technology. The two pictorial elements
are configured together to form an 'E', a pneumonic for Escorts.

1.6 Key Persons

Name Designation
Rajan Nanda CEO
G B Mathur Secretary
Hardeep Singh Director
M G K Menon Director
Nikhil Nanda Joint Managing Director
O K Balraj Exe. VP & Group Chief Financial Officer
P S Pritam Director
Rajan Nanda Chairman and Managing director
S A Dave Director
S C Bhargava Director
S Sridhar Chief Executive Officer
1.7 Subsidiaries
 6

 Escorts Asset Management Ltd.

 Escorts Automotive Ltd.
 Escorts Agri Machinery
 Escorts Class Ltd.
 Escorts Construction Equipment Ltd.
 Escorts Heart Institute and Research Centre Ltd
 Escorts Hospital and Research Centre Ltd.
 Escorts Securities Ltd.
 Escorts Telecommunication Ltd.
 Esconet Services ltd.
 Cellnext Solutions Pvt. Ltd.
 I Serv India Solutions Pvt. Ltd.
 Escosoft Technologies Ltd.
 Escosoft Technologies (USA) Ltd.
 Escosoft Technologies (UK) Pvt. Ltd.
 Escosoft Singapore Pvt. Ltd.
 E-Soft (Mauritius) Holdings Ltd.
 Escotel Mobile Communication Ltd.
 Escotel Telecommunication Ltd.
 7

Chapter -2

Agri machinery group

Introduction
Agri machinery group is the part of Escorts Ltd. In 1960, parent
company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture
into tractors. Having pioneered farm mechanization in the country, Escorts has
played a pivotal role in the agricultural growth of India for over five decades. One
of the leading tractor manufacturers of the country, Escorts offers a
comprehensive range of tractors, more than 45 variants starting from 25 to 80
HP. Escort, Farmtrac and Powertrac are the widely accepted and preferred brands
of tractors from the house of Escorts.

1.1Features of AMG
Escorts - AMG has Tractor manufacturing capacity of 72000 / annum which is the
highest in Asia at one location. Its manufacturing operations are divided in Four
plants as-

 KMC
 Component Plant
 Tractor Assembly Plant
 Crankshaft & Hydraulic Plant

Component Plant consists of Machine shops in which all major castings such as
Engine blocks, Gear Box housings, Differential housings are being machined along
with Gears & Shafts. Machine shop consists of State of the Art machines such as
CNC Horizontal Machining Centers, CNC Turning Centers and variety of other
precision machines, including Gear Hobbing and Shaving machines, etc. It is
important to note that all critical components are machined in house.

Tractor Assembly Plant is divided into two lines as Farmtrac Line and the
Powertrac Line. Farmtrac Line is a composite line that has machining as well as
assembly activities of Engine, Transmission & Tractor whereas on Powertrac line
 8

only Assembly activities of Engine, Transnmission& Tractor are being carried out.
Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop
facilities. Engine Shop has State of the Art testing facilities that includes AVL
make Eddy Current Dynamometers in Engine Test House.

Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and
Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all
Tractor models are being machined. It has State of the Art machines such as Rotary
Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as
well as Assembly activities where critical parts of tractor hydraulics such as
Distributor, Hydraulic Cylinder, etc are being machined and assembled. It has
State of the Art Honing and other precision machines.

1.2 Turn Over

 Present Turn over US$ 30 million.
 Presently Production 72,000 tractors per annum.
 Production will rise to 100,000 tractors per annum in 2 years.
 Procurement value will rise to almost US$ 45 million in that period.
 Presently 387 suppliers of which over 95% are India domestic.

1.3 Product

Table 2.1 Product

Product Brand
Escort E-325 Josh, E-335, MPT
JAWAN
Tractors
Hero, Champion, FT-40,
Farmtrac FT-45, FT-50, FT-60, FT-
70

PT 425, PT434, PT-439,

 9

Powertrac PT- 445, PT-4455

Crop solution Rotavator FT Hero, FT Champion

Laser leveler Farmtrac 60 ,Farmtrac 65

MB Plough
Combrine Harvester FT 65, FT70
Egines Escorts G15, G20, G25, G30
Lubricants Farmtrac Gear oil, FT15W40
Transmission Oil, Engine
oil

1.4 Awards
a). Greentech Environment Excellence Award-2011-Knowledge
Management Centre (KMC) has bagged the Gold Category award in Engineering
Sector instituted by Greentech Foundation, Delhi for outstanding performance in
“Environment Management”
b). Escorts Agri Machinery (EAM) wins accolades at INSSAN-Employees
of EAM participated in various competitions organised by the Indian National
Suggestion Scheme Association New Delhi (INSSAN) at ESSEX farms,
Convention Centre, New Delhi on 3rd and 4th June 2011. INSSAN is a platform to
recognise the value of employees for their intelligence, experience, attitude and
feelings.
c). Escorts won Flower Festival Awards 2011 -organised by Haryana Urban
Development Authority.
d). Recognition of Escorts R&D Centre renewed for next five years i.e. up to 31st
March 2016 based on R&D Projects under taken during last three years.
e). Company was the First Winner in Solid Model Contest 2011- this award is
about the focus on 3D imaging and predictive analysis to reduce the number of
physical prototype to save time, cost and energy consumption.
 10

Chapter-3

KMC

Introduction
Escorts Knowledge Management Center unites professional
expertise with long practical experience in Product Design, Computer Aided
Engineering (Simulation & Virtual Testing), Product Evaluation & Testing. It is in
about 10000 s.m area. Escorts expertise in this area has been developed from
nearly six decades of knowledge & experience in designing and innovating
products and machines for escorts group's own manufacturing companies.
Knowledge management centre have many depart as Design, testing, metrology
etc.

3.1Design
In this section there are design of engine, transmission, vehicle
are being done. For this purpose they use

 I-DEAS / NX 3-D Modeling & Assembly

 Pro – Engineer
 AUTOCAD (2-D)
 11

Figure 3.1a Figure 3.1b

Real axle and differential

Figure 3.2

Engine

Design Simulation & Verification using FEA tools

 12

a)b) Pre processing (Meshing)

c)d) Structural analysis
e)f)  Thermal analysis
g)h) Non linear analysis
i) j)  Dynamic analysis
k)l)  Fatigue analysis
m)n) Optimization of structure
o)p) Multi-body dynamics including flexible body

3.2 Testing
In testing department testing of engine, transmission and tractor testing are done. It
includes engine test lab, transmission lab and tractor lab.

3.2.1Engine - Rigorous testing at the state of art Engine Test Lab

includes

 Friction Measurement- For friction measuring motoring dynamometer is

used. In this test the engine is first run up to the desired speed by its own
power and allowed to remain at the given speed and load conditions for
some time so that oil, water, and engine component temperatures reach
stable conditions. The fuel supply is then cut-off and dynamometer is
converted to run as a motor to drive for the engine at the same speed at
which it was previously running. The power supply to the motor is
measured which is a measure of the friction of the engine. It is about
22kW for 34hp engine.
 Governing Test-This test is performed at high idle speed, rated speed and
an intermediate speed.RPM is decreased in steps of 20 and it is observed at
what RPM maximum power is obtained. For a good engine, the difference
between maximum power RPM and the RPM at which the test is being
performed should not be more than 100-120 RPM.
 Gaseous & Particulate Emission Evaluation- Flame Ionization Detector
is used for HC emission. Bosch smoke meter is used for smoke
 13

measurement.

 Endurance Test - This test is done to estimate the life of the engine. This
test is generally performed on a new engine or an engine with some part
modified. The test procedure depends on type of modification done. A
new engine is run continuously for 3000 hours. After every 40 hours
engine oil is checked, every 100 hours FTP test is done and in every 500
hours engine oil is checked.

 Oil Consumption Evaluation- This test is done for oil consumption

evaluation. In this test power is measured by dynamometer and fuel
consumption is measured.

3.2.2 Vehicle testing – For vehicle there are mainly fatigue test, hydraulic lift
testing, field test and noise test are done.

 Track test- In this test tractor is runs on a track having cleats, or

grousers.
 14

Figure 3.3
Test Track

 PTO performance-This is done by the help of power take off

dynamometer which measure engine power at the power take-off. This
dynamometer has range of power and torque. PTO is 540 rpm at 1710
erpm.
 Power lift- This test is done by power lift set up. In this test lift is
continuously lifting the weight of 1050 kg .
 Noise testing- Sound meter are used for this purpose. This gives the 81
dB.
 Vibration testing – Vibration testing is done using Vibration
measurement instruments consists of

  B&K 3560 Pulse Multi Analyzer System

  16 channel Data Acquisition
  I-DEAS Test Data Analysis Software (TDAS)

This set up gives frequency in 1 to 100 Hz.

3.3 Metrology

Facilities for the measurement of component dimensions using the following

equipment:
3D CMM with software-A coordinate measuring machine is a 3D device
for measuring the physical geometrical characteristics of an object. This
machine may be manually controlled by a computer control.
 15

Figure 3.4

Trimos Height measuring system

Trimos Height measuring system- Trimos hight gauge is used for hight
measurement.
Profile Projector with optical eye & software- It employed for inspecting
and comparing very small and complex parts.
Portable Surface roughness measuring equipment
Conventional instruments
 16

Chapter-4

Assembly Plant

Introduction
The final processed parts from the various parts of production
shop and Heat Treatment reach the assembly Shop. Escorts have two assembly
shop different for each powertrac and farmtrac. In farmtrac assembly line
assembled 120 tractor per day and powertrac capacity is 80 tractor per day. For
lifting the component there are hydraulic lift are used and for small part the used
roller. Conveyor is used for moving in forward direction. The various parts reaches

the assembly shop only after being washed, cleansed and dried, which takes place
when the different parts are on their way to assembly shop. The above washing
process takes place automatically i.e. the machinist has to drop the final Part on the
roller conveyor, and the parts reach the assembly shop after being automatically
washed and dried.

We were advised to walk within the yellow line boundary because of the safety
measures.

The assembly shop can be divided into various subparts being assembled. These
groups are:

 Rear Line
 Transmission Assembly
 Engine Assembly Line
 Front Line
 Paint Shop
 Wheel Assembly

4.1Assembly Layout
 17

Engine
sub
assembly

Differenti Rear axle Gearbox Engine Front axle

al sub assembl assembly assembly
assembly assembly y

Gear
box sub Paint
assembl
y
assembl
y

Radiator Rear hood Front Rear wheel

and air fitment wheel fitment
filter fitment

Accessorie Hydraulic
s lift test
 18

Figure 4.1

Assembly layout

4.2 Real assembly

Real assembly line is starting of assembly shop. Before the
various differential parts such as bp shaft, differential cage etc. are assembled, the
various sub-assembly of parts listed above are performed in the sub units. In the
first unit, both the bp shafts are fitted with various components such as circular
clips, bearings etc. to be able to be assembled to the differential Cage. This
constitutes the assembly of cross bar, planetary gear, planetary gear cover, and
crown wheel etc.

The various bolts required making the assembly of about parts and integral one are
bolted using a pneumatic bolter gun.After this, the differential cage is collected
from the conveyor firstly fitted with the necessary bearing races. Then the
differential Cage unit and the bp shaft are assembled, making up a complete one
unit.

The Axles are assembled in a different sub assembly shop. First rear axle wash and
dry and then fixed wheel side bearing and there on the whole unit along with the
bull gears is assembled to the differential Cage. Differential cover assemble after
these assemblies.

4.3 Transmission Assembly

The gear box assembly is the third stage of the
assembly unit in which the gear box is assembled. Firstly, the gearbox cage is
collected from the conveyor roller and successively parts such as the counter
shafts, clutch shafts, main shaft along with the ball bearings are assembled to the
unit. There is separate sub unit assembling the planetary cage and gears, which is
then attached to the gear box output shaft.
 19

First gear on main shaft with 38 teeth and reverse gear with 38 teeth, second gear
with 35 and and third with 28 teeth. This is the constant mesh type transmission.

After assembly of the transmission there is leakage testing is perform. In this test
first gear box is full of oil and then sealed. After that the pressure is increase up to
10 bar. Then the by the motor power the clutch shaft is revolve at 2700 rpm. This
test check meshing of gears. After that whole unit is assembled to the main line
and make a complete one unit.

4.4Assembly of Engine and Clutch Mechanism

First there is clutch assembly. Single clutch organic coil type
clutch are fitted. Before the engine assembly there is assembly of various other
accessories such as Foot board, battery clamp and other links such as accelerator
pedal link, clutch link, brake link etc.

Engine from sub assembly are assembled to the main line. A four stoke 3 cylinder
diesel engine first assembled at the engine sub assembly.

The various links and mechanism between the engine and the gear box is fastened
together and the whole integral unit is checked for its complete accessories etc. In
all the above stages of assembly, the skilled workers are used to accomplish all the
stages of assembly. But they are also held by the pneumatic bolt guns and the over
head automatic conveyors and the alarm conveyor etc to make their job easy.
 20

Figure 4.2 Figure 4.3

Clutch and brake pedal fitting Engine and fuel tank

4.5 Front axle and accessories and paint

After engine fitting there is assembly of front axle. After front
axle there are steering assembly of the steering and accessories. Then clutch pedal
and break is fitted. Fuel tank is fitted after this. After the whole assembly goes the
lift for painting in the paint shop. The painting purpose there is cap fitted on bolts
of wheel hub to protecting from paint.
 21

Figure 4.4

Front axle fitment

Paint shop is completely automatic. In the paint shop first there is degressing ,
water rinsing and demineralized water rinsing. After that air blowing is done. Paint
Baking Oven removes the moisture from water-based coatings and adhesives.
After that unsmasking and touch up and painted the body.
 22

Figure 4.5

Painted body of tractor

4.6 Rear and Front wheel fitting

After painting there is fitting of rear wheel with
tyre size of 12.4×28 and front wheel fitment with the tyre size of 6×16. After
fitting the wheels there is following fitment.
 23

Figure 4.6

Rear wheel fitting

Fan and Motor

Rear hood

Radiator and coolant

Steering wheel

Mirror

Air filter

Front light
 24

Seat

Silensor

Figure 4.7

Fitment of radiator

4.7 Final Testing

Final testing of tractor is lift testing and the test of track. At
there a hydraulic force of 1050 kg applied and testing is done.
 25

Chapter-5

Steady of Cylinder Block Machining

Introduction
Cylinder block of four stroke four cylinder diesel engine is done after
casting. A cast cylinder block is comes from vendor. Machining of cylinder block
is done at 10 different machines. E4.286- It is the machining line of cylinder block
In this line 4 stroke engine cylinder block is machined. The total displacement of
the engine is 2860 cc.

5.1BSM 01- Block straight milling –This operation perform in duplex milling
machine. It has two rotating cutting rotor.

Figure 5.1
 26

Cylinder block

Target- To have a rough cutting on sump phase and head face.

Depth of cut is 1.5 mm on each face. So cutting about 3 mm
Procedure- Locate the component from party dowel. Party dowel is used to
clamping the job. Party dowel is given by the party (supplier) which gives casting
to the company.
It rest on TCS (Tappet cover side) and clamp on NPS (Name plate side). This will
help in keeping job in correct position.
Rotation of cutter was clockwise when view from back side of spindle.
Separate motor for compressor, oil/water are used.
Feeds are automatic. Operator need to place the job and remove it.
Use the pully crain to lift the object. 6 buttons are provide in the lifter( Up, Down,
North, South, East, west).Now roller are provide to tilting the objects. This is done
by chain mechanism.
Now in order to remove chips and other waste like dust, compressed air is used.
Hight of the cylinder block (i.e. distance between sump and head face ) is =
411.5±0.2 mm
Sump face width is equal to 121±0.2 mm.
Time gear side to bell housing side is equal to 431.5±0.2 mm

5.2Machine-2
Mazak horizontal centre –NEXUS 8800 II- In this machine mazatrol software is
used. There is continuous supply of machine (oil and water) to work as coolant and
cleaner.CNC machine here is used for Various operation on head and sump face
and cap sheet (finishing, drilling, counter drill, and tapping).

Procedure- Locate from party dowel and clamp.

Party dowel – TCS (Tappet cover side)

 27

Clamp-NPS (Name plate side)

Setup-1

Head face- On the head face there are 18 holes (with tapping) are produced for
tightening the cylinder head. After that there is 9 more hole produce for the water
passage. These holes are drilled only. One more hole produce for oil passage.

Dimensions

For tightning of cylinder head 18 holes drilled of Φ 10.5 mm

And counter drilled of Φ 12.5 mm

For water passage

4 holes drilled of Φ 10 mm

5 holes drilled of Φ 6 mm

For oil passing

One through hole of Φ 7 mm

Sump Face-On the sump face there are two more dowel are created for further
machining process.

Dimensions 13H7

On sump face there are 14 more holes are produce.

Dimensions drill of Φ 8.5 mm

tappping of M10×1.5

And then two small dowels are created of Φ5 size.

 28

One more hole produce of Φ18.5 and tapped of M20×1.5

One dowel of 16H8 produced.

Set up-2
With the help of manufactured dowel fixed sump face and perform on the
NPS, TGS, BHS, TCS.

Time gear side-On this face there is 2 holes drilled and one dowel machined.

Table 5.1 Hole dimensions

Side Size
TGS Φ6.8 drill M8×1.25 Tapping

Φ18 drill M20×2 Tapping

16H8 dowel
TCS 2 holes Φ8.5 drilled M10×1.6 Tapping
3 bore Φ36

NPS Φ16.5 M18×1.5 Tapped

Φ16.5 M18×3/4 ″ Tapped
Φ16.5 M18×1/4 ″ Tapped
Φ16.5 M18×1/8 ″ Tapped

Φ9 M10×1
BHS Φ12.5 M14×1.5
Φ10.2 M12×1.75

5.3Machine-3
 29

HMC-25 -This machine programmed with FANUC CODE. There are two types
of fixtures .Here we use mechanical rather than hydraulic. To mechanically these
fixtures we use close wise.

Use crain to hold the job and place on fixture with dowel on sump face.
Now put close wise and tighten the screw. We use brake (hydraulic) pedal in order
to start /stop. After this rotation of fixture is done and now door were closed and
change pallet and start the program.

This is the special type of machine. On this machine we can perform all the
operations that are done earlier And this machine check the tool life also. This
gives OEE (Overall equipment efficiency) of the tool.

On this machine we perform oil gallering. This is done from crank to cam
at 29 degree and from crank to idler at 18 degree. Oil gallery from crank to cam is
longer than crank to idler.

For change the pallet we use this program.

MOI M60 EOB Insert

Cycle start

Alternative of this machine are BD03 (block drill) and GBD01 (gear
block drill-gear box department)- In this machine drilling is done with the help of
radial drilling machine. These drilling machine two fixtures of 29 degree and 18
degree are made so that drill can be done in straight manner.

5.4Machine-4
 30

BSM12 (Block straight milling) - on this machine milling and notching is done at
one of the side used as a stopper for bushes. On this machine cutter have 10 side
mill and 5 end mill.

5.5Machine -5
BNR04 (Block Nut turner) -For main bearing cap bolt tightening first already
finished caps are put on the web and mechanically tightened using BNR.

5.6Machine -6
Now block again comes on the HMC25 (horizontal milling centre)
for crank, cam and idler boring. Here semi finishing is done. First rough boring is
done and there after semi finished boring is done. And thereafter it goes to vertical
milling centre.

5.7Machine -7
VMC26 (vertical milling centre milling centre) – At VMC26 tappet boring is done.

Here it create 4 holes of Φ 25 mm

dimensions

Also along these tappets are created 4 cams working. At this stage
checking of all dimensions are done hare. For checking all dimension they use ring
gauge, Bore dial gauge, Go not go plug are used.

5.8Machine -8
BSB14 – Block straight boring -2 way boring. Here boring of
crank, cam and idler is being finished. Boring is done from both end since it is two
way. In this machine boring of crank/cam is done from one side and boring of idler
from another side.
 31

5.9Machine-9
BWT4 (Block washing machine) - This is a washing machine with both
type of block air and block water cleaning. And final inspection is done over here.

5.10Machine-10
BBP (block bush pressing) -For this purpose BEMCO
hydraulic press is used. This is used to put bush inside the cam hole. Capacity -25
kW.
 32

Chapter-6

Bolt Selection and Failure

Introduction
Bolts are defined as headed fasteners having external threads
that meet an exacting. Bolt are manufactured in a wide range of materials from
common steel to titanium, plastic and other exotic materials. Many materials are
further separated into different grades to describe specific alloy mixtures,
hardening processes, etc. In addition, some materials are available with a variety of
coatings or plating to enhance the corrosion resistance, or appearance of the
fastener.

Selection of bolt depend on the torque requirement. When replacing bolt, it is

generally best to match what you are replacing. Replacing a bolt with a stronger
one is not always safe. Harder bolts tend to be more brittle and may fail in specific
applications. Also some equipment is designed so that the bolts will fail before
more expensive or critical items are damaged. In some environments such as salt
water galvanic corrosion must also be considered if changing fastener materials.

6.1Bolt Grading
There are three grades of bolt in common used. Most bolts which
you will come across will only deviate slightly from these three grades. The lowest
grade is 4.6, commonly known as commercial grade. Next comes grade 8.8, known
as structural grade, and finally, the highest grade is 12.9, known as high tensile
bolts. In between these there are many grades are used such as 4.8, 5.6, 9.8 and
10.9 etc.
 33

4.6

Ultimate Tensile strength Yield Strength is

4*100MPa 60% of tensile Strength

i.e. 0.6*4*100=240MPa

Table 6.1 Bolt grade and there material

Minimum Tensile Minimum

Size Range Proof Yield Tensile
Class Head Marking Material
(mm) Strength Strength, Strength
(106 Pa) (106 Pa) (106 Pa)

Low or medium
4.6 M5 - M36 225 400
carbon steel
240
 34

Minimum Tensile Minimum

Size Range Proof Yield Tensile
Class Head Marking Material
(mm) Strength Strength, Strength
(106 Pa) (106 Pa) (106 Pa)

M1.6 - Low or medium

4.8 310 420
M16 carbon steel

340

Low or medium
5.8 M5 - M24 380 520
carbon steel

420

Medium carbon
8.8 M16 - M36 600 830
steel, Q & T

660

M1.6 - Medium carbon

9.8 650 900
M16 steel, Q & T

720

Low carbon
10.9 M5 - M36 830 1040 martensite steel,
Q&T
940
 35

Minimum Tensile Minimum

Size Range Proof Yield Tensile
Class Head Marking Material
(mm) Strength Strength, Strength
(106 Pa) (106 Pa) (106 Pa)

M1.6 - Alloy steel, Q &

12.9 970 1220
M36 T

1100

6.2How do you tighten a bolt?

The general objective from a tightening process is to achieve a
consistent bolt preload. Controlling the torque during tightening and completing
subsequent inspection checks to ensure that the specified torque is being achieved
are common ways that this objective is implemented.

When applied torque and the resulting tension (preload) in the bolt are measured
during tightening and plotted on a graph, there is a linear relationship between the
torque and the tension. The bolt tension is directly dependent, and proportional to,
the applied torque. This is illustrated by the graph, which is based upon
experimental results, that is shown in the diagram above. From such test results it
is possible to establish the appropriate torque for a required bolt preload that may
be preload.
 36

Figure 6.1

Torque distribution chart

It is known that approximately 50% of the tightening torque is

dissipated in overcoming friction under the bolt head or the nut face (whichever is
the face that is rotated). Typically only 10% to 15% of the overall torque is
actually used to tighten the bolt, the rest is used to overcome friction in the threads
and on the contact face that is being rotated (nut face or bolt head). This is
illustrated in the pie chart shown above. Relatively small changes in the nut face
friction can have a significant effect on the bolt preload. As more torque is perhaps
needed to overcome friction, less remains for the bolt extension and hence as the
effect of adversely reducing the preload. If the friction under the nut face is
reduced , then, for a given torque, the bolt preload will be increased.

Grade 12.9 bolts are tightened with a torque wrench, right up to their 90% proof
load. There is no other effective way to tighten a grade 12.9 bolt. Automotive
manuals will give the tightening torque required. Grade 12.9 bolts do not work
 37

effectively with spring washers or shakeproof washers. These don't bite into the
hardened surface of the bolt. There are only two ways of adding extra security to
grade 12.9 bolts. Use Loctite on the threads or drill the heads and wire the bolts. It
is possible to buy pre-drilled cap screws. Mating surfaces of a 12.9 bolted joint are
not painted. For serious work, never re-use a fully tensioned 12.9 bolt.

Grade 8.8 bolts are tightened by the part turn method, torque wrench, or by using
load indicating washers. In the part turn method, the bolt is done up to snug tight,
and then advanced one, two or three flats of the hexagon, depending on the size,
length etc. The torque wrench method is used commonly, often in the form of an
air operated rattle gun. Special load indicating washers, such as Coronet washers
can be used. These have dimples which indent the mating surface. A feeler gauge
is used to determine the pre-load. Grade 8.8 Bolts are used in High Strength
Friction Grip applications. If this is the case, the mating surfaces must not be
painted or galvanized. For added security of the joint , use any one of the plethora
of systems such as spring washers, shake proof washers, Loctite, wired heads, split
pins and castle nuts, locking tabs, lock nut or patented nut systems (Nyloc is
common). For serious work, use castle nuts, either with split pins or wired together
in groups. Also for serious work, do not re-use fully tensioned grade 8.8 bolts,
Nylocs, split pins etc.

Grade 4.6 bolts are not pre-tensioned in the joint. They are tightened to snug tight
only. For all intents, this means a reasonable hand effort on a spanner. Use good
springy chrome-moly spanners, and never put an extension bar on the spanner. All
of the security systems available for 8.8 bolts are available on 4.6 bolts. If you
need much more than a spring washer, question whether the joint really requires an
8.8 bolt. Mating surfaces of a grade 4.6 bolted joint are usually painted prior to
assembly.

6.3 Torque Specifications

Recommended bolt torque values are listed in the
following tables. For critical applications, as determined by Toro, either the
recommended torque or a torque that is unique to the application is clearly
identified and specified in the service manual .These torque specifications for the
installation and tightening of bolt shall apply to all bolt which do not have a
 38

specific requirement identified in the service manual. The following factors shall
be considered when applying torque:

Cleanliness of the bolt, use of a thread sealant (Loctite), degree of lubrication on

the bolt, presence of a prevailing torque feature, hardness of the surface underneath
of the bolt head, or similar condition which affects the installation . As noted in
the following tables, torque values should be reduced by 25% for lubricated bolts
.To achieve the similar stress as a dry bolt. Torque values may also have to be
reduced when the bolt is threaded into aluminum or brass. The specific torque
value should be determined based on the aluminum or brass material strength, bolt
size ,length of thread engagement, etc .The standard method of verifying torque
shall be performed by marking a line on the bolt (head or nut) and mating part,
then back off bolt 1/4 of a turn. Measure the torque required to tighten the bolt
until the lines match up.

Table 6.2
Torque requirement

Size Grade 8.8 (N-cm) 10.9 (N-cm) 12.9(N-cm)

# 6 - 32 UNC 170±20 260±20

# 6 - 40 UNF 190±20 280±20
# 8 - 32 UNC 330±30 460±45
# 8 - 36 UNF 350±30 482±45
# 10 -24 UNC 475±45 674±70
# 10- 32 UNF 540±45 765±70
1/4 - 20 UNC 1125±100 1580±170
1/4 - 28 UNF 1300±100 1800±170
5/16- 18 UNC 2250±280 3390±340
5/16- 24 UNF 2540±280 3670±340
N-m N-m
 39

3/8 - 16 UNC 41±4 58±5

3/8 - 24 UNF 47±4 68±5
7/16 - 14 UNC 68±7 68±9
7/16 - 20 UNF 75±7 104±9
1/2- 13 UNC 102±11 142±14
1/2- 20 UNF 115±11 163±14
5/8- 11 UNC 203±20 285±27
5/18- 11 UNF 230±20 325±27
3/4- 10 UNC 359±34 508±47
3/4- 16 UNF 407±34 569±47

6.4 ISO Standard of bolts

M12×1.75×80-8.8

Nominal dia Pitch Length Grade of bolt

 40

Figure – 6.2

Bolt View

k –Head Hight da- Fillet Transition Diameter

ds- Shank Diameter lf -Fillet Length

e- Across Corner r- Fillet Radius

s - Across flats pa - Pitch

c- Washer Face Thickness dw - Washer Face Diameter

 41

Table 6.3 Bolt ISO standard

Nominal Bolt Diameter M1.6 M2 M2.6 M3 M4 M5 M6 M8 M10
pa 0.35 0.4 0.45 0.5 0.7 0.8 1 1.25 1.5
b 9 10 11 12 14 16 18 22 26
b ref c 15 16 17 18 20 22 24 28 32
d 28 29 30 31 33 35 37 41 45
c max 0.25 0.25 0.25 0.40 0.40 0.50 0.50 0.60 0.60
min 0.10 0.10 0.10 0.15 0.15 0.15 0.15 0.15 0.15
da max 2.0 2.6 3.1 3.6 4.7 5.7 6.8 9.2 11.2
ds Nom.=maximum 1.6 2.0 2.5 3.0 4.0 5.0 6.0 8.0 10.0
Product A min 1.46 1.86 2.36 2.86 3.82 4.82 5.82 7.78 9.78
Grade B 1.35 1.75 2.25 2.75 3.70 4.70 5.70 7.64 9.64
dw Product A min 2.27 3.07 4.07 4.57 5.88 6.88 8.88 11.63 14.63
Grade B 2.3 2.95 3.95 4.45 5.74 6.74 8.74 11.47 14.47
e Product A min 3.41 4.32 5.45 6.01 7.66 8.79 11.05 14.38 17.77
Grade B 3.28 4.18 5.31 5.88 7.50 8.63 10.89 14.20 17.59
lf max 0.6 0.8 1 1 1.2 1.2 1.4 2 2
Nom. 1.1 1.4 1.7 2 2.8 3.5 4 5.3 6.4
product A max 1.225 1.525 1.825 2.125 2.925 3.65 4.15 5.45 6.58
k Grade min 0.975 1.275 1.575 1.875 2.675 3.35 3.85 5.15 6.22
product B max 1.3 1.6 1.9 2.2 3.0 3.26 4.24 5.54 6.69
Grade min 0.9 1.2 1.5 1.8 2.6 2.35 3.76 5.06 6.11
kwe Product A min 0.68 0.89 1.10 1.31 1.87 2.35 2.70 3.61 4.35
Grade B 0.63 0.84 1.05 1.26 1.82 2.28 2.63 3.54 4.28
r min 0.1 0.1 0.1 0.1 0.2 0.2 0.25 0.4 0.4
Nom.=maximum 3.20 4.00 5.00 5.50 7.00 8.00 10.00 13.00 16.00
s Product A min 3.02 3.82 4.82 5.32 6.78 7.78 9.78 12.73 15.73
Grade B 2.90 3.70 4.70 5.20 6.64 7.64 9.64 12.57 15.57

Nominal Bolt Diameter M12 M16 M20 M24 M30 M36 M42 M48 M56
pa 1.75 2 2.5 3 3.5 4 4.5 5 5.5
B 30 38 46 54 66 - - - -
b ref c 36 44 52 60 72 84 96 108 -
d 49 57 65 73 85 97 109 121 137
c max 0.6 0.8 0.8 0.8 0.8 0.8 1.0 1.0 1.0
min 0.15 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3
da max 13.7 17.7 22.4 26.4 33.4 39.4 45.6 52.6 63
ds Nom.=maximum 12 16 20 24 30 36 42 48 56
Product A min 11.73 15.73 19.67 23.67 - - - - -
Grade B 11.57 15.57 19.48 23.48 29.48 35.38 41.38 47.38 55.26
dw Product A min 16.63 22.49 28.19 33.61 - - - - -
Grade B 16.47 22 27.7 33.25 42.75 51.11 59.95 69.45 78.66
e Product A min 20.03 26.75 33.53 39.98 - - - - -
 42

Grade B 19.85 26.17 32.95 39.55 50.85 60.79 71.3 82.6 93.56
lf max 3 3 4 4 6 6 8 10 12
Nom. 7.5 10 12.5 15 18.7 22.5 26 30 35
product A max 7.68 10.18 12.715 15.215 - - - - -
k Grade min 7.32 9.82 12.285 14.785 - - - - -
product B max 7.79 10.29 12.85 15.35 19.12 22.92 26.42 30.42 35.5
Grade min 7.21 9.71 12.15 14.65 18.28 22.08 25.58 29.58 34.5
e
kw Product A min 5.12 6.87 8.6 10.35 - - - - -
Grade B 5.05 6.8 8.51 10.26 12.8 15.46 17.91 20.71 27.65
r min 0.6 0.6 0.8 0.8 1 1 1.2 1.6 2
Nom.=maximum 18 24 30 36 46 55 65 75 85
s Product A min 17.73 23.67 29.67 35.38 - - - - -
Grade B 17.57 23.16 29.16 35.00 45 53.8 63.1 73.1 82.8
Nominal Bolt Diameter M12 M16 M20 M24 M30 M36 M42 M48 M56
a
p 1.75 2 2.5 3 3.5 4 4.5 5 5.5
B 30 38 46 54 66 - - - -
b ref c 36 44 52 60 72 84 96 108 -
d 49 57 65 73 85 97 109 121 137
c max 0.6 0.8 0.8 0.8 0.8 0.8 1.0 1.0 1.0
min 0.15 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3
da max 13.7 17.7 22.4 26.4 33.4 39.4 45.6 52.6 63
ds Nom.=maximum 12 16 20 24 30 36 42 48 56
Product A min 11.73 15.73 19.67 23.67 - - - - -
Grade B 11.57 15.57 19.48 23.48 29.48 35.38 41.38 47.38 55.26
dw Product A min 16.63 22.49 28.19 33.61 - - - - -

6.5Bolt Failure
When a threaded fastener cannot sustain the expected
loading and becomes detached, a significant loss may occur. Although rare,
bolt failure has caused wheel detachment on vehicles, structural failure in
buildings, and crashes of aircraft. This article presents several examples of
bolt failures that have been involved in serious losses. The claims
professional is usually involved early in the analysis of the accident and is
influential in the early decisions as to the failure analysis of the threaded
fastener involved. Through a review of these case studies, the claims
professional can gain insight into how to handle future assignments
involving bolt induced losses.
 43

6.5.1Failure as a result of an overload

Many accidents can be characterized as an impact with a
non-compliant object such as a truck impacting a concrete bridge support. In these
cases, bolt failure due to overload can occur. Figure 6.3a is a view of a bolt that
fractured in the threaded area. The 45 degree full-slant fracture surface indicates
high tensile loads. The fine, gray appearance of the fracture surface is consistent
with a sudden overload failure. In this case, other bolts on the mechanical part had
failed, transferring the load to the remaining bolt shown in Figure 1, resulting in an
overload. Figure 6.3b is a view of the fracture surface of a steering gear output
shaft of a large truck. The truck was involved in an accident and a question arose
as to the role of the steering unit as a possible cause. Microscopic examination of
the fracture shows a full-slant fracture surface (about 45 degrees) and evidence of a
shear-face tensile fracture, characteristic of an overload. It was concluded that the
fracture of the output shaft was most likely a result of the accident and not a cause.
Figure 6.3c is a view of a similar fracture surface at the threaded end of a wheel
spindle with it’s characteristic 45 degree fracture surface and fine gray appearance.
This is a typical overload during a vehicle rollover accident.

(a) (b) (c)

Figure6.3

Failure as a result of an overload

6.5.2Failure due to lack of locking mechanism

 44

In order to prevent bolts from loosening over time, various locking

mechanisms are employed. They include lock washers, locking nuts, jam nuts,
mechanical deformations, wire wrap, cotter pins, metal locks, expansion anchors,
helical coils and polymer locking compounds. Machinery that is subject to
vibratory environments usually is equipped with some sort of locking mechanism.
If the locking mechanism is not applied to the machinery during manufacture, a
catastrophic event may result. Figure 6.4a is a view of a hoist transmission used in
a large crane. The bolt shown in Figure6.4b was found out of position after the
crane transmission “jumped out of gear” dropping a heavy load. In Figure 6.4a, the
arrow points to the location of the bolts. Specifications called for a polymer
locking compound to be applied to the bolt threads to prevent backing out. No
compound was found on the bolt threads or in the threaded hole. Consequently,
over a period of time, the bolts loosened, resulting in the loss of control to the shift
fork in the transmission.

(a) Figure 6.4 (b)

Failure due to lack of locking mechanism

6.5.3Metal fatigue-
Metal fatigue is the phenomenon characterized by progressive
crack growth during cyclic loading. A crack is often initiated at a flaw or stress
riser (sharp notch) in a part. Cyclic forces such as vibrations or repeated impact
cause the crack to increase in size until the part can no longer sustain the load, and
a final fracture occurs. The arrows point to the initiation sites of the fatigue crack.
The small lines or striations on the metal surface show the advance of the crack
from the exterior to the inside of the bolt. The rutted gray area in the middle of the
bolt is the area of final fracture where the bolt cross-section was reduced and the
bolt could not carry the load.
 45

6.5.3Failure from improper torque

When threaded fasteners are utilized, the amount of tightening or
bolt torque is often important. Motor vehicle wheel studs require torques ranging
from about 100 ft-lbs for smaller vehicles to over 400 ft-lbs for large trucks. The
appropriate torque is required in order to prevent relative flexing of the two parts
being fastened and to assure an acceptable mechanical connection. Bolt failures as
a result of improper torque have occurred in automobile applications (See Claims
Magazine, December 1995).Figure 6.5 shows a part of the stud that was bearing on
the wheel rim causing severe wear of the thread, another indicator of insufficient
bolt.

Figure6.5

Failure from improper torque

6.5.4Failure from improper design

It is generally considered poor design to allow significant
alternating shear or bending forces in the vicinity of the threaded section of the bolt
since the threads form a stress riser and tend to initiate fatigue cracks, as happened
in this case. A better design would be to utilize a bolt with a shorter threaded
section so that the unthreaded shank material is at the shear area of the bracket.
This eliminates the stress riser from the threaded section and increases the effective
bolt diameter.

6.5.5Failure from improper manufacture

 46

Figure 6.6 is a view of a failed tie rod end bolt, a critical steering system
component in an automobile. The vehicle suddenly pulled to the right after
traveling over a bump in the road. The fracture surface revealed an area of
progressive fracture that had been occurring over time. This was initiated by a heat
treating related defect in the outer surface of the tapered shank. The crack grew by
metal fatigue and finally failed when traveling over a modest road surface
perturbation. The driver suddenly experienced extreme difficulty in steering the
vehicle and lost control. With little evidence of an extreme force application at the
right rear suspension, it appeared unusual that a bolt would fracture from an
overload in such a manner. The bolt was removed and tested. The exterior surface
hardness was found to vary considerably along the bolt length, resulting in a stress
discontinuity at the fracture surface

Figure6.6

Failure from improper manufacture

 47

Chapter-7

Conclusion

Summer training in Escorts Ltd. really helped me to familiarize myself to the practical
knowledge of industrial production and processes. T h e w h o l e training period was
very interesting, instructive and challenging. Through this training I was able to gain
new insights and more comprehensive understanding about the real industry working
condition and practice.

I got the idea of working of automatic CNC machines, Testing techniques of Diesel
engine, tractors and different processes used in machining of cylinder block and
Assembly plant. All of this valuable experience and knowledge that I have gained were
not only acquired through the direct involvement in task given but also through other
aspect of the training such as work observation, interaction with operators, supervisor
and other peoples involved in the process.

In assembly plant i saw how tractor are assembled. I get knowledge about different-
different sub assemblies of tractor assembly plant. Differential sub assembly,
transmission sub assembly, transmission testing, paint of body and different sub
stations.

It was a good idea and good chance to expose to the work environment that we will
have to face and practice after we graduate. As a result of the training now I am more
confident to enter the employment world and build my future career.
 48

References

1. http://euler9.tripod.com/bolt-database/22.html
2. http://www.escortsagri.com/
3. http://www.standardsbis.in/Gemini/search/BasicSearch.action?sear
chValue=hexagonhead bolts#
4. http://www.boltscience.com/pages/quality.htm
5. http://www.boltscience.com/pages/nutorbolttightening.htm
6. Introduction to Design Behavior of Bolted Joint by John H.
Bickford.
7. http://www.scribd.com/doc/51438283/1364-1
8. Material given to me by the company