INDUSTRIAL TRAINING at Crankshaft And Hydraulic Division Faridabad INTRODUCTION On 17th October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. The Escorts Group, is among India's leading engineering conglomerates operating in the high growth sectors of Agro machinery Construction and material handling equipments Railway equipments Auto components Manufacturing of a Crankshaft It Is The Only Crankshaft Manufacturing Group In Northern India. Forged Crankshaft come from Bharat Forging, Pune and Mahindra Forging.Eg. E-312 Complete Machining Operations are performed in CHD. Weight of Forged Crankshaft 25 to 26 Kg Weight of Machined Crankshaft -21to 23 Kg Various processes Involved are as follows : Components of a Crankshaft Crank Pins P1, P2, P3 Journals J1, J2, J3, J4 FOD Gear End Counter weights FACING AND CENTERING It is the step which marks the beginning of the Manufacturing of the Crankshaft. Facing and Centering resembles to Giving Legs To A Child. It being the very first step should be operated under intense care as it may lead to rejection of material at the very beginning. Defects While Facing And Centering Defects may arise due to negligence of the operator in checking the tool bit after each operation. Though it can be removed in futher process of facing and turning of flywheel end but still counts the efficiency of a worker in performing the job Eccentricity This is mainly due to carelessness of the operator in placing the Job on the machine. Eccentricity mainly lead to rejection of material and cannot be rectified. ROUGH AND FINISH TURN JOURNAL J1,J2,J3 & J4 This operation involves giving rough turning to the four Journals J1, J2, J3 & J4 of the crankshaft. It is no hard and fast rule that it should be done only after Centering and Facing. Operation Performed on Miven CNC Turning Centre manufactured by Warner and Swasey. FINISH TURN GEAR END DIA AND RECENTER This operation involves the turning operation to be performed on the Gear End which is just before Journal J1. It roughly turns the gear end dia so as to perform further operations on the crankshaft. FINISH TURN FLYWHEEL END DIA, DRILL AND BORE Turning of Flywheel End is done on WSU-12 CNC Turning Centre manufactured by Kirloskar Warren Swasey. Different Crankshafts have different Turning Designs. DEFECTS WHILE TURNING Turning is mostly operated in CNC so human error is negligible. But its cutting Tool should be checked after each operation which may lead to create grove on the crankshaft thus Rejecting it. DRILLING (Oil Holes, Cross Hole Drilling, Reaming, Lapping) Drilling holes is basically done to provide a flow to the engine oil at the time engine runs. This avoids consequences like wear and tear of crankshaft. CHAMFERING & RADIAL DRILL HOLE Chamfering is done immediately after drilling operation. It is done to avoid any accident in the plant due to sharp edges of the drilled holes. Radial holes are mostly done on crankshafts bigger in size. On smaller crankshafts radial hole is not done. Radial Drill is done in Crank Pins only. DEBURRING This operation is done to Clean all Loose chips including breaking point of Oil holes. It also deburrs all sharp corners. These chips are removed so as to avoid any obstruction in Induction hardening. INDUCTION HARDENING Benefits of Induction Hardening- Zero Breakdown System PLC Based System. Operator & Maintenance Friendly Advanced Latest Technologies Fastest Calibration Services and Spare support Backup. User Friendly, easy diagnostic due to PLC & MI Trolley Movement motorized : No Fatigue to Operator Mistake proof all diameters get case hardened in Auto Cycle- Consistency in Hardening Quality TEMPERING Tempering is done to remove stresses induced in the crankshaft while induction hardening. Temperature deg C. Give proper time of 2 hrs. 48 CS can be tampered in the well at a time. WET GRINDING (Pin, Angular and Cylinder) The main objective for Grinding is To give Ultrafine Finish to the Parts. To remove Ovality To remove Run-out Marposs Gauge is engaged in all the Machine so as to stop the Process as soon as desired dia. is attained. The Only Difference between Grinding FOD and other grinding machine is that its Grinding wheel has a different shape and is at an angle of 30 deg to the Crankshaft DRESSING OF GRINDING WHEEL Dressing is the Process of leveling the Grind wheel. Diamond cutter which is present at the other end of the wheel. Dressing is done mainly to : Avoid Ovality in the crankshaft. Avoid Run out of the Crankshaft. Improves cutting tendency of the wheel. MAGNA FLUX CRACK DETECTION Kerosene oil is mixed with fluorescent Powder and spilled on electrically charged Crankshaft. Then UV Rays are made to fall on the Crankshaft and cracks are detected. The cracks can be of Hair size as well. After crack detection the Crankshaft is Passed through a demagnetizer which discharges the Crankshaft Multi Tapping (Gear end and FOD) It consists of various radial drills aligned in the required manner. Crankshaft after being clamped is drilled from both the ends (Gear end and FOD ) The depth of drill is pre determined. It is done for further attachments at both the ends. 3 drills are there on the Gear End while 6 on the FOD side. MILL WOODRUFF KEYWAY Milling of Woodruf key is done on a manually operated machine. Operator must ensure exact location of the woodruff keyway and exact depth. LAPPING Lapping is an old method of achieving surface finish on Lathe. Crankshaft runs on different RPM for different dia. Like : For Journal/FOD/Tail End lapping RPM For Pin Lapping - 80 RPM Belt used is known as Emery Belt. AERO DYNAMIC BALANCING Best way of improving the performance of the engine is by balancing it. first step in the understanding crankshaft balancing is to understand the purpose of the counterweights if the counterweight are too heavy, material must be removed by drilling or milling the counterweight. the counterweight are too light, weight must be added to the counterweights or drilling is done the other counter part. FINAL AUDIT After Balancing each crankshaft is ready to be dispatched thus a final audit is performed. Each Crankshaft has to go through the Final Audit. It is done by Quality Department. Each and Every Dimension of the Crankshaft is checked thoroughly so as to avoid any complaint from other plants. It works in three shifts. Color Coding is done on the Crankshaft like Red color is done on the rejected ones while green on the Approved ones. WASHING AND OILING Now the Crankshaft is ready to be a part of the Engine. So before storing crankshaft, proper washing and oiling is done on them so as to prevent them from Rusting. STORE After the complete Manufacturing of the Crankshaft it is very necessary to place the Crankshaft with Intense Care so as to avoid any Damage to them. Thus the crankshaft are Carried by the Folk Lifter to the Specified area which is also known as the Store. Here different Models of Crankshafts are stored. And they are dispatched as soon as Order is received from the other plant. THANK YOU FOR YOUR TIME HAVE A GOOD DAY