Internship Training Report

1. INTRODUCTION
1.1 COMPANY OVERVIEW: EVM VOLKSWAGEN
EVM Volkswagen was established in 2008 by EVM Group, Kerala’s well-
renowned automobile dealer with showrooms and service centres across the state. EVM
Group comes from a business family with more than 68 years of experience in Kerala
market. You’ll find the latest models of all popular Volkswagen vehicles at your
disposal at our state-of-the-art showrooms. Our showrooms are well-maintained by a
team of experienced and certified technicians. At EVM, customers get the first priority.
We believe in providing the best products and services to our esteemed customers
without compromising on quality. Our friendly sales staff will help you decide the best
car model for you so that you enjoy your drives along with family and friends.
Customers can avail a wide range of financing options, Volkswagen genuine
accessories and spare parts at all our showrooms.

1.2 VOLKSWAGEN MODELS

Currently, Volkswagen offers six models distributed across three automobile
classes – Sedans, Hatchbacks and Sport Utility Vehicles (SUVs or Sport Ute) in the
Indian market. The Volkswagen car Images and Volkswagen videos say it all - the
elegancy, the styling and class of Volkswagen automobiles.

Volkswagen sold only 99 units of the GTI in India. The hot hatch is powered
by a 1.8-liter TSI putting out 189 BHP and 250 Nm of torque. Equipped with a 7-speed
DSG gearbox, the Polo GTI is claimed to reach a top speed of 233 km/hr.

Sedans:
Volkswagen Ameo | Volkswagen Vento | Volkswagen Passat
Hatchbacks:
Volkswagen Polo | Volkswagen Polo GT | Volkswagen Polo GTI
SUVs:
Volkswagen Tiguan

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Fig 1: Volkswagen Models

1.3 FACILITIES

Fig 2: EVM Volkswagen, Maradu

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3. WORKSHOP LAYOUT

Fig 3: Workshop Layout

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Fig 4: Volkswagen Workshop

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4. WORKING IN WORKSHOP
4.1 FEATURE OF WORKSHOP

• Equipped with hi-tech lift machined for lifting the car to repair top bottom parts.
• All technicians have their own equipment’s and machinery.
• They have a very large floor, sufficient area of working.
• Time to time sweepers clean the workshop to maintain the good working
environment.
• All the major & minor faults would be found by manually or through software.
• The workshop has well maintained illumination and air circulation.
• All working and inventory are controlled computerised.

4.2 SAFETY

Working on vehicles can be a fun, exciting, and rewarding career. However,

repair shop owners and their staff need to ensure the proper safety precautions and rules
are implemented and followed at all times. Safety measures help protect employees
from accidental injuries to themselves, their co-workers, customers, and the vehicles
they are repairing. The following is a list of general safety tips every repair shop should
use to keep everyone safe.
• Never smoke in or near repair bays or garages. Vehicles contain flammable and
combustible fluids which can easily be set on fire if a hot ash from a cigar or
cigarette were to come into contact with such materials.
• Keep work areas clean and organized. Pick up tools and use tool cabinets to
keep walkways clear and free from clutter.
• Never wear loose clothing or clothing that is ripped or torn. To prevent
employees from wearing unacceptable attire, it is recommended to obtain
customized uniforms and work apparel from a qualified uniform service
company.
• Wear protective gear at all times, as appropriate for the repair. Goggles, gloves,
and ear protection should be worn when making certain types of repairs.
• Make sure fire extinguishers are easily acceptable and appropriate for all
potential fire types. In the event of a fire, extinguishers need to be accessed

Dept. of Automobile Engg. 5 IIPE, NEllikuzhy

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quickly and be charged with the right materials to put out the type of fire: i.e.,
gas, oil, electrical, and so on.
• Always disconnect the battery when working on electrical systems and
near/around electrical wiring. Even when the vehicle is off, there is still the
potential for current to pass through electrical wiring.
• Never place hands, tools, or other objects near the engine while it is running.
The moving parts and components could cause injury to a person or the vehicle
itself.
• Never work underneath a vehicle unless it has been properly supported. Raising
the vehicle off the ground to access the underside requires verifying it is stable,
and that there is no risk of the vehicle falling on top of the mechanic.
• Always remove the keys from the ignition switch. Never leave the key in the
ignition switch, as the key can draw an electrical charge from the battery. Also,
avoid unplugging fuses and wiring harnesses while the key is in the “on”
position. Otherwise, there is a risk of electrical shock, and/or electrical spikes
that may damage electronic parts and wiring.
• Be aware of the vehicle’s temperature before beginning any work. The engine,
manifold, exhaust system, and radiator could be hot and cause skin burns. Plus,
the radiator coolant is still pressurized.

Dept. of Automobile Engg. 6 IIPE, NEllikuzhy

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5. OBJECTIVES OF TRAINING

• To learn the servicing of au tomobiles.

• To study the corporate workshop culture.

• To search the benefits and scope in global market.

• To improve the technical skills.

• To improve the knowledge about different machines.

• To take the information of industry working method.

• Taking the idea about group working.

• To improve the knowledge about tools used in maintenance section.

• To compare the theoretical knowledge with industry practical work.

• Improvement of personal skills.

Dept. of Automobile Engg. 7 IIPE, NEllikuzhy

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6. TYPES OF MACHINES
There were different machines out there in the workshop. Every machine has
their unique quality of performance. They are discussed below: -

6.1 LATHE MACHINE

A lathe is a machine tool that rotates the workpiece on its axis to perform
various operations such as cutting, sanding, knurling, drilling, or deformation, facing,
turning, with tools that are applied to the workpiece to create an object with symmetry
about an axis of rotation.

Fig.5: Lathe Machine

6.2 BORING MACHINE

In machining, boring is the process of enlarging a hole that has already been
drilled (or cast), by means of a single-point cutting tool (or of a boring head containing
several such tools), for example as in boring a gun barrel or an engine cylinder. Boring
is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a
tapered hole. Boring can be viewed as the internal-diameter counterpart to turning,
which cuts external diameters.
There are various types of boring. The boring bar may be supported on both
ends (which only works if the existing hole is a through hole), or it may be supported
at one end (which works for both through holes and blind holes).

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Line boring (line boring, line-boring) implies the former. Back boring (back
boring, back-boring) is the process of reaching through an existing hole and then boring
on the "back" side of the workpiece (relative to the machine headstock). Because of the
limitations on tooling design imposed by the fact that the workpiece mostly surrounds
the tool, boring is inherently somewhat more challenging than turning, in terms of
decreased tool holding rigidity, increased clearance angle requirements (limiting the
amount of support that can be given to the cutting edge), and difficulty of inspection of
the resulting surface (size, form, surface roughness). These are the reasons why boring
is viewed as an area of machining practice in its own right, separate from turning, with
its own tips, tricks, challenges, and body of expertise, despite the fact that they are in
some ways identical.

6.3 SURFACE GRINDING

Surface grinding is used to produce a smooth finish on flat surfaces. It is a
widely used abrasive machining process in which a spinning wheel covered in rough
particles (grinding wheel) cuts chips of metallic or non-metallic substance from a
workpiece, making a face of it flat or smooth.

6.4 HYDRAULIC PRESS

A hydraulic press is a device (see machine press) using a hydraulic cylinder to
generate a compressive force. It uses the hydraulic equivalent of a mechanical lever,
and was also known as a Bramah press after the inventor, Joseph Bramah, of England.

Fig.6: Hydraulic press

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The hydraulic press depends on Pascal's principle: the pressure throughout a

closed system is constant. One part of the system is a piston acting as a pump, with a
modest mechanical force acting on a small cross-sectional area; the other part is a piston
with a larger area which generates a correspondingly large mechanical force. Only
small-diameter tubing (which more easily resists pressure) is needed if the pump is
separated from the press cylinder. Pascal's law: Pressure on a confined fluid is
transmitted undiminished and acts with equal force on equal areas and at 90 degrees to
the container wall. A fluid, such as oil, is displaced when either piston is pushed inward.
Since the fluid is incompressible, the volume that the small piston displaces is equal to
the volume displaced by the large piston. This causes a difference in the length of
displacement, which is proportional to the ratio of areas of the heads of the pistons,
given that volume = area × length. Therefore, the small piston must be moved a large
distance to get the large piston to move significantly. The distance the large piston will
move is the distance that the small piston is moved divided by the ratio of the areas of
the heads of the pistons. This is how energy, in the form of work in this case, is
conserved and the Law of Conservation of Energy is satisfied. Work is force applied
over a distance, and since the force is increased on the larger piston, the distance the
force is applied over must be decreased. Bramah's basic idea is also exploited in
hydroforming. Hydraulic presses are commonly used for forging, clinching, moulding,
blanking, punching, deep drawing, and metal forming operations. Rod attached to the
camshaft is pressed with the help of hydraulic power then it comes down then pressure
is so high that the rod attached to camshaft comes out easily with less effort. The
precaution should be applied.

Dept. of Automobile Engg. 10 IIPE, NEllikuzhy

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7. CLUTCH

A clutch is a mechanical device that engages and disengages the power

transmission, especially from driving shaft to driven shaft. Clutches are used
whenever the transmission of power or motion must be controll ed either in
amount or over time (e.g., electric screwdrivers limit how much torque is
transmitted through use of a clutch; clu tches control whether automobil es
transmit engine power to the wheel s). In the simplest application, clutches
connect and disconnect two rotating shafts (drive shafts or line shafts) . In these
devices, one shaft is typically attached to an engine or other power uni t (the
driving member) while the other shaft (the driven member) provides output power
for work. Whi le typically the motions involved are rotary, linear clutches are
also possible. In a torque-controlled drill, for instance, one shaft is driven by a
motor and the other drives a drill chuck. The clutch connects the two shafts so they
may be locked together and spin at the same speed (engaged) , locked together
but spinning at different speeds (slippin g), or unlocked and spi nning at different
speeds (disengaged).

Fig 7: Clutch Plate

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8. TRANSMISSION
A transmission is a machine in a power transmission system, which provides
controlled application of the power. Often the term transmission refers simply to the
gearbox that uses gears and gear trains to provide speed and torque conversions from a
rotating power source to another device. In British English, the term transmission refers
to the whole drive train, including clutch, gearbox, prop shaft (for rear-wheel drive),
differential, and final drive shafts. In American English, however, the term refers more
specifically to the gearbox alone, and detailed usage differs the most common use is in
motor vehicles, where the transmission adapts the output of the internal combustion
engine to the drive wheels. Such engines need to operate at a relatively high rotational
speed, which is inappropriate for starting, stopping, and slower travel. The transmission
reduces the higher engine speed to the slower wheel speed, increasing torque in the
process. Transmissions are also used on pedal bicycles, fixed machines, and where
different rotational speeds and torques are adapted.

Fig.8: Car Transmission

Often, a transmission has multiple gear ratios (or simply "gears") with the
ability to switch between them as speed varies. This switching may be done manually
(by the operator) or automatically. Directional (forward and reverse) control may also
be provided. Single-radio transmissions also exist, which simply change the speed and
torque (and sometimes direction) of motor output. In motor vehicles, the transmission
generally is connected to the engine crankshaft via a flywheel and/or clutch and/or fluid

Dept. of Automobile Engg. 12 IIPE, NEllikuzhy

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coupling, partly because internal combustion engines cannot run below a particular
speed. The output of the transmission is transmitted via the driveshaft to one or more
differentials, which drives the wheels. While a differential may also provide gear
reduction, its primary purpose is to permit the wheels at either end of an axle to rotate
at different speeds (essential to avoid wheel slippage on turns) as it changes the
direction of rotation. Conventional gear/belt transmissions are not the only mechanism
for speed/torque adaptation. Alternative mechanisms include torque converters and
power transformation (e.g., diesel-electric transmission and hydraulic drive system).
Hybrid configurations also exist. Automatic transmissions use a valve body to shift
gears using fluid pressures in conjunction with an ECM. Early transmissions included
the right-angle drives and other gearing in windmills, horse powered devices, and steam
engines, in support of pumping, milling, and hoisting. Most modern gearboxes are used
to increase torque while reducing the speed of a prime mover output shaft (e.g. a motor
crankshaft). This means that the output shaft of a gearbox rotates at a slower rate than
the input shaft, and this reduction in speed produces a mechanical advantage, increasing
torque.
A gearbox can be set up to do the opposite and provide an increase in shaft
speed with a reduction of torque. Some of the simplest gearboxes merely change the
physical rotational direction of power transmission. Many typical automobile
transmissions include the ability to select one of several gear ratios. In this case, most
of the gear ratios (often simply called "gears") are used to slow down the output speed
of the engine and increase torque. However, the highest gears may be "overdrive" types
that increase the output speed Early transmissions included the right-angle drives and
other gearing in windmills, horse powered devices, and steam engines, in support of
pumping, milling, and hoisting.
Most modern gearboxes are used to increase torque while reducing the speed of
a prime mover output shaft (e.g., a motor crankshaft). This means that the output shaft
of a gearbox rotates at a slower rate than the input shaft, and this reduction in speed
produces a mechanical advantage, increasing torque. A gearbox can be set up to do the
opposite and provide an increase in shaft speed with a reduction of torque. Some of the
simplest gearboxes merely change the physical rotational direction of power
transmission. Many typical automobile transmissions include the ability to select one
of several gear ratios. In this case, most of the gear ratios (often simply called "gears")
are used to slow down the output speed of the engine and increase
Dept. of Automobile Engg. 13 IIPE, NEllikuzhy
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torque. However, the highest gears may be "overdrive" types that increase the output
speed The simplest transmissions, often called gearboxes to reflect their simplicity
(although complex systems are also called gearboxes in the vernacular), provide gear
reduction (or, more rarely, an increase in speed), sometimes in conjunction with a right-
angle change in direction of the shaft (typically in helicopters, see picture). These are
often used on PTO powered agricultural equipment, since the axial PTO shaft is at odds
with the usual need for the driven shaft, which is either vertical (as with rotary mowers),
or horizontally extending from one side of the implement to another (as with manure
spreaders, flail mowers, and forage wagons). More complex equipment, such as silage
choppers and snow blowers, have driven with outputs in more than one direction. The
gearbox in a wind turbine converts the slow, high-torque rotation of the turbine much
faster rotation of the electrical generator. These are much larger and more complicated
than the PTO gearboxes in farm equipment. They weigh several tons and typically
contain three stages to achieve an overall gear ratio from 40:1 to over 100:1, depending
on the size of the turbine. (For aerodynamic and structural reasons, larger turbines have
to turn more slowly, but the generators all have to rotate at similar speeds of several
thousand rpm.) The first stage of the gearbox is usually a planetary gear, for
compactness, and to distribute the enormous torque of the turbine over more teeth of
the low-speed shaft.[3] Durability of these gearboxes has been a serious problem for a
long time. Regardless of where they are used, these simple transmissions all share an
important feature: the gear ratio cannot be changed during use. It is fixed at the time
the transmission is constructed. For transmission types that overcome this issue, see
Continuously variable transmission, also known as CVT.

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9. DIFFERENTIAL

A differential is a particular type of simple planetary gear train that has the
property that the angular velocity of its carrier is the average of the angular velocities
of its sun and annular gears. This is accomplished by packaging the gear train so it has
a fixed carrier train ratio R = - 1, which means the gears corresponding to the sun and
annular gears are the same size. This can be done by engaging the planet gears of two
identical and coaxial epicyclic gear trains to form a spur gear differential. Another
approach is to use bevel gears for the sun and annular gears and a bevel gear as the
planet, which is known as a bevel gear differential.

Fig 9: Differential

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10.AXLE
An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the
axle may be fixed to the wheels, rotating with them, or fixed to the vehicle, with the
wheels rotating around the axle. In the former case, bearings or bushings are provided
at the mounting points where the axle is supported. In the latter case, a bearing or
bushing sits inside a central hole in the wheel to allow the wheel or gear to rotate around
the axle. Sometimes, especially on bicycles, the latter type axle is referred to as a
spindle.

10.1 DRIVE AXLE

Fig 10: Axle

An axle that is driven by the engine or prime mover is called a drive axle.
Modem front wheel drive cars typically combine the transmission (i.e., gearbox and
differential) and front axle into a single unit called a transaxle. The drive axle is a split
axle with a differential and universal joint between the two half axles. Each half axle
connects to the wheel by use of a constant velocity (CV) joint which allows the wheel
assembly to move freely vertically as well as to pivot when making turns. In rear-wheel-
drive cars and trucks, the engine turns a driveshaft (also called a propeller shaft or tai l
shaft) which transmits rotational force to a drive axle at the rear of the vehicle.

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11. SUSPENSION
Suspension is the system of tires, tire air, springs, shock absorbers and linkages
that connects a vehicle to its wheels and allows relative motion between the two.
Suspension systems serve a dual purpose — contributing to the vehicle's road
holding/handling and braking for good active safety and driving pleasure, and keeping
vehicle occupants comfortable and a ride quality reasonably well isolated from road
noise, bumps, vibrations, etc. These goals are generally at odds, so the tuning of
suspensions involves finding the right compromise. It is important for the suspension
to keep the road wheel in contact with the road surface as much as possible, because all
the road or ground forces acting on the vehicle do so through the contact patches of the
tires. The suspension also protects the vehicle itself and any cargo or luggage from
damage and wear. The design of front and rear suspension of a car may be different.

Fig.11: Suspension of Front and Rear End

Obviously, any four-wheel vehicle needs suspension for both the front wheels
and the rear suspension, but in two-wheel drive vehicles these can be very different
configuration. For front-wheel drive cars, rear suspension has few constraints and a
variety of beam axles and independent suspensions are used. For rear-wheel drive cars,
rear suspension has many constraints and the development of the superior but more
expensive independent suspension layout has been difficult. Four-wheel drive often has
suspensions that are similar for both the front and rear wheels.

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11.1 DOUBLE WISH BONE

Fig 12: Double Wish Bone

In automobiles, a double wish bone suspension is an independent suspension
design using two wishbone-shaped arms to locate the wheel Each wishbone or arm has
two mounting points to the chassis and one joint at the knuckle. The shock absorber
and coil spring mount to the wish bones to control vertical movement. Double wishbone
designs allow the engineer to carefully control the motion of the wheel throughout
suspension travel, controlling such parameters as camber angle, caster angle, toe
pattern, roll center height, scrub radius, scuff and more.

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12. TWO POST LIFT

Fig 13: Two Post Lift

A two post above ground lift is designed to raise cars and trucks for easy access
to wheel assemblies and the underside of the vehicle. A two post above ground lift is
normally mounted to an existing concrete surface. Minimal concrete depth required for
a two post above ground lift is four inches. Thicker concrete is required for two post
lifts exceeding a 12,000 LB. capacity. The li ft consists of two upright columns, four
adjustable arms attached to a carriage assembly, two hydraulic cylinders, an
electric/hydraulic power unit, and a variety of hoses, pulleys, and cables. This is the
most common style of two post above ground lift. There are several European
manufacturers building above ground lifts that use an extended screw/nut configuration
powered by an electric motor.

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13. WHEEL ALIGNMENT

Wheel alignment, sometimes referred to as breaking or tracking, is part of
standard automobile maintenance that consists of adjusting the angles of wheels to the
car manufacturer specifications. The purpose of these adjustments is to reduce tire
wear, and to ensure that vehicle travel is straight and true (without "pulling" to one
side). Alignment angles can also be altered beyond the maker's specifications to obtain
a specific handling characteristic. Motorsport and off-road applications may call for
angles to be adjusted well beyond "normal", for a variety of reason

Fig 14: Wheel Alignment

13.1 BENEFITS OF WHEEL ALIGNMENT

• Increase Fuel Efficiency. When your automobile isn't aligned correctly, your
wheels aren't working together they way that they should.

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• Reduce Expensive Auto Repairs

• Experience Smoother Driving.
• Improve Vehicle Safety.
• Increase the Life of Your T
13.2 CAMBER ANGLE

Camber angle is the angle made by the wheels of a vehicle; specifically, it is the
angle between the vertical axis of the wheels used for steering and the vertical axis of
the vehicle when viewed from the front or rear. It is used in the design of steering and
suspension. If the top of the wheel is farther out than the bottom (that is, away from the
axle), it is called positive camber; if the bottom of the wheel is farther out than the top,
it is called negative camber.

Fig 15: Camber Angle

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14. BRAKE
A brake is a mechanical device which inhibits motion, slowing or stopping a
moving object or preventing its motion. Most brakes commonly use friction between
two surfaces pressed together to convert the kinetic energy of the moving object into
heat, though other methods of energy conversion may be employed. The brake disc (or
rotor in American English) is usually made of cast iron, but may in some cases be made
of composites such as reinforced carbon–carbon or ceramic matrix composites. This is
connected to the wheel and/or the axle. To retard the wheel, friction material in the
form of brake pads, mounted on a device called a brake calliper, is forced mechanically,
hydraulically, pneumatically, or electro magnetically against both sides of the disc.

Friction cause the disc and attached wheel to slow or stop.

Fig 16: Brake

14.1 ANTI LOCKING BRAKING SYSTEM

An anti-lock braking system (ABS) is a safety anti-skid braking system used on
land vehicles, such as cars, motorcycles, trucks and buses. ABS operates by preventing
the wheels from locking up during braking, thereby maintaining tractive contact with
the road surface. ABS is an automated system that uses the principles of threshold
braking and cadence braking which were once practised by skilful drivers with earlier
non-ABS braking systems. ABS operates at a very much faster rate and more
effectively than most drivers could manage. Although ABS generally offers improved
vehicle control and decreases stopping distances on dry and slippery surfaces, on loose
gravel or snow-covered surfaces, ABS may significantly increase braking distance
while still improving steering control.

Dept. of Automobile Engg. 22 IIPE, NEllikuzhy

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15. CONCLUSION
It was great experience to work with highly trained technicians at EVM
Volkswagen service centre. For me this training is quite fruitful. I got exposure of how
to implement theoretical knowledge in practical use. Get idea about different
mechanisms and electronics control used in modern Hi-tech Volkswagen car.

Dept. of Automobile Engg. 23 IIPE, NEllikuzhy