AXLE HOUSING

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About SCOOTER INDIA
Incorporated in 1972, Scooters India Limited is an ISO 9001:2000
Company, situated at 16 Km mile stone, South-west of Lucknow, the
capital of Uttar Pradesh on NH-25 and is well connected by road, rail
and air.
It is a totally integrated automobile plant, engaged in designing,
developing, manufacturing and marketing a broad spectrum of
conventional and non-conventional fuel driven 3-wheelers.
Company’s plant owes its origin to M/s. Innocenti of Italy from which
it bought over the plant and machinery, design, documentation,
copyright etc. The company also possesses the world right of the trade
name LAMBRETTA / LAMBRO.
In 1975, company started its commercial production of Scooters under
the brand name of Vijai Super for domestic market and Lambretta for
overseas market. It added one more wheel to its product range and
introduced three wheelers under the brand name of
VIKRAM/LAMBRO. However, in 1997, strategically, the company
discontinued its two-wheeler production and concentrated only on
manufacturing and marketing of 3 wheelers. These three wheelers
have become more relevant in the present socio-economic
environment as it transports goods and passengers at least cost.
The company has its own marketing network of Regional Sales
Offices all over India, catering to customer’s requirements in the areas
of sales and services.

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DEPARTMENTS
The organization has various departments to perform different activities
competently. SIL has an organized system to control different activities.
Personnel & administration department looks after the employees’ welfare,
medical benefits, conveyance facilities, maintains their personal records and
controls their regularity. It also takes care of the security for the organization.
Marketing & services department looks after the marketing of the products,
provide services to the customer and regulates the activities in its various
regional offices.
Materials control the purchasing of the raw material, keep an eye on the costof
the material in the market, store the different materials and products and
establish a company-vendor relationship. Workshop manufactures different
products in steps in different lines. Design & development is the prime creative
unit for the organization. It brings out some brilliant design with modern
technologies. Finance & accounts section keeps track on the financial growth
and the maintenance of various types of accounts.
ASSEMBLY
The components manufactured in plant as well as those bought have to be
finally assembled to make the productthree wheelers. In the process many sub
assemblies, too, are involved. However, two main assemblies worth mentioning
are engine assembly and vehicle assembly. Both are conveyorised. Every 5
minutes a three wheeler rolls down the conveyor. The vehicle conveyor has 23
stations. Speed can be adjusted to meet increasing demand.
MACHINE SHOP
Machine shop has a wide variety of machines like General purposemachine,
Special purposemachine, Multispindle automatic machine, Single spindle
automatic machine etc; which are mainly working on single shift through eight
different lines. Line no 2 is basically machining the aluminium components.
Crank shaft and cylinder machining is usually done on line no 3. Line no. 4 is

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the Grinding line where the grinding process is done. Heat treatment is
performed in line no 5, while different turning of shafts and gear shaping and
shaving are carried on line no 6.Line no. 7 includes the functioning of gear
manufacture process mainly broaching, hobbing, finish turning, gear shaving
etc. machining of different levers, centre less grinding of tubes and shafts,
serration / thread rolling operations is achieved in line no. 8 & lastly different
components are fed in two other lines by line no. 9. Blank turning of gear and
machining of parts is done on multi spindle and single spindle automatic
machine. Engine components and some vehicle component are the prime
production.
FABRICATION
The fabrication operations are carried out in two departments viz. Press Shop
and Welding Shop. The Press Shop is equipped with 20 presses ranging from 10
tons to 550 tons. Presses are fed by sheets cut to size on shearing machines of
3000x6 & 2500x3 mm. size. Components ranging from washer to cabin roof
and door(1000x1200 mm.) are being processedin this shop.
The Welding Shop is equipped with battery of Spotwelding, MIG welding,
Seam welding as well as Arc welding machines. CO2 welding is extensively
used for getting close tolerance on welded structures. The department has its
own auxiliary shop for maintenance of tools and dies.
PAINT SHOP
Paint shop includes three sections namely Paints section, spray phosphating
section, pickling. Paint section includes two convention painting spray booth &
one electrostatic painting plant. The first one is called conventional primer
where mainly frame paintings are done. The equipments used for conventional
painting are Bullow's 230 spray gun and pressure fit tanks (we prepare paints).
The various types of frames like Diesel 750, Mini petrol, Mini diesel, Diesel
floor mounting, Diesel Nepal, Diesel scrubber, Electric vehicle are painted here.
The other conventional booth is known as conventional finish booth. Here the
frame accessories like cabin front, roof top, front fork, axle housing are painted.

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In electrostatic plant the accessories of the frame, the component of lighter
weight and minimum size like silencer, pillar and various brackets are painted
here.
In spray phosphating the main work is to clean the components before painting
or to make surface according to paint requirement. After phosphating the
products goes to passivation for converting ferrous to ferric for paintings need.
The products come from welding shop, press shop and machine shop to
phosphating, and after the process is being done the products go to vehicle
assembly. The pickling department is mainly for maintaining the surface of
heavily corroded materials.
FOUNDRY
The foundry, most modern in this part of the country, can produce all grades of
grey cast iron as well as S. G. iron. In fact, it had been innovative to find new
processes of modulisation, for which it was granted 2 patents. Equipped with an
Induction Melting furnace, Shell Moulding Machines & Core Shooters, Green
Sand Moulding facilities, Isothermal Heat Treatment Furnace, one sand muller
machine, two shot blasting machine, two set jolting machines for green sand
moulding, fettling and shot blasting equipments, its normal range of production
weighs upto 8 Kgs. on a pattern plate of 450x600 mm. However, foundry men
are trained to make casting even of 1 ton weight if emergent requirement arises.
The foundry is not fully loaded with its captive requirement. Spare capacity is
utilised for producing sophisticated castings of prestigious customers like
BHEL, Indian Railways, Aerospace, Brakes India Limited, Crompton Greaves
limited.The induction furnace has a capacity of 1.3 tons. The two types of
moulding is been done here. 1. Shell moulding 2. Green sand moulding. The
foundry can manufacture a wide range of products namely Differential housing,
Differential cages, Power transimission wheel, Crankcase flange, Magneto
motor, Engine output flange, Adapter plate for electric vehicle, Cylinder for
both Vikram 410 petrol version and Vikram 750 diesel version.

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ABSTRACT
 AXLE AND AXLE HOUSING :-
An axle is a theoretical or
actual crossbarsupporting a vehicle, on which one or more wheels turn.
An axle assembly on a car or truck is the set of components that allows
the wheels to rotate freely. Two wheels are usually connected by a shaft
known as AXLE. It sits inside an axle housing, and is held in place by
bearings and/or bushing that allows it to rotate within the axle housing.
 NEED OF HOUSING-
Due to continuous force exerted by the
wheel, axle faces large amount of pressure which can damage the axle,
damage to the axle itself can cause the entire assembly to fail, so as the
housing acts as a protective layer for the spinning axle.
LUBRICATION of the axle is also made possible becauseof the housing.
It provides the smoothsurface for the motion of the axle, which reduces
wear and tear and frictional losses between the axle and axle housing.

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FUNCTION OF REAR-
DRIVE AXLE
The rear-drive axle or rear axle is often suspended from the bodyor frame of the
vehicle by leaf spring attached to the axle housing. Vehicles with other types of
springs position the rear axle with control arms.
A rear axle performs several functions. These includes-
 Changing the direction of drive shaft rotation by 90° to rotate the axle
shafts.
 Providing a final speed reduction between the drive shaft and the axle
shafts through the final drive-drive gears.
 Providing differential action so one wheel can turn at a different speed
than the other, if necessary.
 Providing axle shafts or half shafts to drive the rear wheels.
 Acting as a thrust- and torque reaction member during acceleration and
braking.

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FLOW DIAGRAM
WELDING SHOP
↓
MACHINE SHOP
↓
WELDING SHOP
↓
PAINT SHOP
↓
VEHICLE ASSEMBLY

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RAW MATERIAL
MILD STEEL is the main constituent of this manufacturing.
Mild steel also known as plain – carbon steel, is now the most common form of
steel because its price is relatively low while it provides material properties that
are acceptable for many applications.
It has relatively low tensile strength, but it is cheap and easy to form; surface
hardness can be increased through carburizing.
Low carbonsteel contains approximately 0.05-0.15% carbonmaking it
malleable and ductile.
The density of mild steel is approximately 7.85g/cm³.
The Young’s modulus is 210GPa.
SPECIFICATIONS RHM* RHD** LHM***
Length 588cm 748cm 272cm
Outer diameter 60mm 60mm 60mm
Thickness 6mm 6mm 6mm
*RHM= Right hand mini
**RHD= Right hand diesel
***LHM= Left hand mini

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STEP-1
WELDING SHOP
Following sub steps are involved in the sub assembly of the axial housing in the
welding shop -
MANUAL METAL ARC WELDING
↓
MACHINING
↓
PRESSING
↓
MANUAL ARC GAS WELDING

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1. OBJECTIVE –
To weld the following parts to the circular hollow tube
with the help of Manual metal arc welding process -
a) Bracket 4364.2095
b) Sauker pin 43.44.2140
c) L-bracket 43.04.2066
MATERIALS USED – Mild steel tube, mild steel electrode coated with flux.
MACHINARY USED - Manual metal arc welding machine.
PROCESS DESCRIPTION-
MANUAL METAL ARC WELDING - MMA welding or
informally as stick welding, is a manual arc welding process that uses a
consumable electrode covered with a flux to lay the weld.
An electric current from a welding power supply is used to form an electric arc
between the electrode and metal to be joined. The work piece and electrode
melts forming the weld poolthat cools form a joint.
As the weld is laid, the flux coating of electrode disintegrates, giving off vapour
that serves as a shielding gas and providing a layer of slag, both of which
protects the weld area from atmospheric contamination.
 Welding is done vertically. To hold the tube fixtures are used.
 Low voltage, high current is used.
 AC step down transformer is used for power supply.
 ELECTRODE- GM 20 is medium coated rutile type electrode for all
positions welding. It has stable arc with easy to strike and re-strike and
gives radiographic quality welds. These electrodes are made of mild steel
and coated with different compounds including rutile, calcium, fluoride,
cellulose, and iron powder.
 Length of electrode = 350-450mm
Diameter of electrode = 3.15mm
Voltage= 80-120V

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Current = 90-120A
Protection capacity= 84 %
Arc temperature = 3500 °C
 Optimum distance between base metal and electrode must be around 10-
12 mm, for the effective and proper welding.
 ADVANTAGES –

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A) VERSATILITY- readily applied to a variety of applications and a wide
choice of electrodes.
B) Relatively simplicity and portability of equipment.
C) Low cost.
D) Adaptable to confined spaces and remote locations.
 DISADVANTAGES –
A) Not as productive as continuous wire processes.
B) Likely to be more costly to deposit a given quantity of metal.
C) Frequent stop/starts to change electrode.
D) Relatively high metal wastage.
E) Current limits are lower than for continuous or automatic processes.
 DEFECTS – The most common quality problem associated with this
type of welding is as follows –
A) WELD SPATTER – While not affecting the integrity of the weld,
damages its appearance and increases cleaning cost. It can be caused
by excessively high current, a long arc a condition associated with
direct current characterized by the electric arc being deflected away
from the weld poolby magnetic forces.
B)POROSITY – Arc blow can also cause porosity in weld, as can
joint contamination, high welding speed. Porosity, often not visible
without the use of advanced non-destructive testing methods, is a
serious concernbecause it can potentially weaken the weld.
C)POOR FUSION – Though it is often easily visible, it is caused by
low current, contaminated joint surfaces, or the use of an improper
electrode.
D)SHALLOW PENETRATION- Another detriment to weld
strength, can be addressed by decreasing welding speed, increasing the
current or using small electrodes.
E)UNDERCUT – Undercutting is when the weld reduces the cross-
sectional thickness of the base metal, which reduces the strength of the
weld and workpieces .
F)GAS INCLUSION- Gas inclusion is a wide variety of defects that
includes porosity, blow hole and pipes. The underlying cause for gas

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inclusion is the entrapment of gas within the solidified weld. Gas
formation can be from any of the following causes-
a) High sulphur content in the workpiece or electrode.
b) Excessive moisture from the electrode or workpiece
c) Too short of an arc, or wrong welding current or polarity.
G) CRATER CRACK- Crater cracks occurin the crater when the
welding arc is terminated prematurely. Crater cracks are normally
shallow.
H) LONGITUDINAL CRACK- Longitudinal cracks run along
the length of a weld bead. These are three types-
a) Check crack.
b) Rootcrack.
c) Full centerline crack.

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 RESULT- Hence, the following parts have been welded with the
housing with the manual metal arc welding.
 SAFETY AND PRECATIONS-

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Some common safety and precautions are below which should be
followed during the time of welding-
a) The electric arc is a very powerful sourceof light, including visible,
UV and infrared. Protective clothing and equipment must be worn
during all welding operations.
b) Welding arc are intensely brilliant light. Therefore, the arc should
never be viewed with naked eye.
c) Being closest, the welder needs a helmet to protect his/her eyes and
face from harmful light and particles of hot metal.
d) The hand-held shield is held in the position by the handle. This type of
shield is used by an observer or a person who welds for a short period
of time.
e) Remove all the flammable material such as cotton, oil, gasoline etc.,
from the vicinity of welding.
f) Keep a suitable fire extinguisher nearby at all time. Ensure the fire
extinguisher is in operable condition.
g) Do not leave hot rejected electrode stub, steel scrap, or tools on the
floor or around the welding equipment. Accident and/or fire may
occur.

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2) OBJECTIVE- To machine the weld product, following operation being
performed-
a) Turning
b) Facing
c) Boring
TERMINOLOGIES USED-
 TURNING- This operation is one of the most basic machining
processes.That is, the part is rotated while a single point cutting tool is
moved parallel to the axis of rotation. Turning can be done on the
external surface of the part as well as internally. The starting material is
generally a workpiece generated by other processes suchas casting,
forging, extrusion, or drawing.
Turning can be done manually, in a traditional form of lathe, which requires
continuous supervision by the operator, or by using an automated lathe which
does not..
ADVANTAGES-
a) All materials compatible.
b) Very good tolerances.
c) Short lead time.
DISADVANTAGES-
a) Limited to rotational parts.
b) High equipment cost.
c) Significant toolwear.
d) Large amount of scrap.
e) Part may require several operation and machines.
APPLICATIONS-
a) Machine components, shafts, engine components.

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 FACING-
A single-point turning toolmoves radially, along the end of the
workpiece, removing a thin layer of material to provide a smooth flat
surface. The depth of the face, typically very small, may be machined in a
single pass or may be reached by machining at a small axial depth of cut
and making multiple passes.
ADVANTAGES-
a) After performing facing, the surface becomes smoothand well
finished.
b) Short lead time.
c) Very good tolerances
DISADVANTAGES-
a) Limited to rotational parts.
b) Parts may require several operation and machines.
c) High equipment cost
APPLICATION-

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a) Machine components, shafts, engine components.
 BORING - Boring is the process ofproducing circular internal
profile on a hole made by drilling or another process.It uses single point
cutting toolcalled a boring bar. In boring, the boring bas can be rotated,
or the workpart can be rotated. Machine tolls which rotate the boring bar
against a stationary workpiece are boring machine.
Boring can accomplished on a turning machine with a stationary boring
bar positioned in the toolpostand rotating workpiece held in the lathe
chuck.

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ADVANTAGES- The following are the advantages of the boring-
a) All material compatible
b) Very good tolerance.
c) Low cost.
DISADVANTAGES- The following are the disadvantages of the boring
operation-
a) The material at the bottom of the hole is disturbed by heavy tool.
b) Limited tooling design.
APPLICATIONS-
a) Widely used for manufacturing of the machine components and engine
shafts.
b) Used in manufacturing of axle housing of various vehicle.
 RESULT- Hence, the final productis ready for the further
manufacturing process.
3) OBJECTIVE- To fit the following parts in the housing by using
Hydraulic pressing machine-
a) Axle pin 42.04.2046

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b) Flange 2043
c) Flange 2045
 MATERIAL USED - Axle pin ( 42.04.2046), Flange ( 2043), Flange
(2045), welded housing.
 MACHINARY USED - Hydraulic pressing machine, fixtures.
 PROCESS DESCRIPTION-
HYDRAULIC PRESSING MACHINE- A hydraulic press is a
device using a hydraulic cylinder to generate a compressive force. It uses
the hydraulic equivalent of a mechanical lever, and was also known as
Bramah press, after the inventor, Joseph Bramah of England.
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.
PASCALS LAW – Pressure on a confined fluid is transmitted
undiminished and acts with equal force on equal area and at 90 degrees
to the container wall.
4) OBJECTIVE - To weld the following parts with the help of manual arc
. . gas welding process.
 MATERIALS USED – Finished workpiece after hydraulic pressing,
mild steel wire coated with copper, carbon-di-oxide active gas cylinder.
 MACHINARY USED- Manual arc gas welding machine.

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 PROCESS DESCRIPTION –
MANUAL ARC GAS WELDING- Gas metal arc welding or
welding with shielded gases, as it is often called, is a welding arc process
which utilizes the heat of an electric arc established between a
continuously feeded wire and the workpiece.
During this process the wire will melt and the weld metal is transferred to
the workpiece.
The weld pool is always protected by a shield of gas in order to protect
bith the melting wire and the weld poolfrom the oxygen and nitrogen in
the air. If these gases enter into the shielding gas atmosphere, it may
cause porosities in the weld.
MAG welding is welding in an atmosphere of reacting gases, or as it is
also called Shielded by an active gas. This means that the gas is separated
in the arc and to a smaller or larger extent reacts with the weld pool.
SPECIFICATION OF COPPER WIRE –
Mild steel wire is coated with copperwire is used.
Diameter- 0.2mm to 0.8mm
Voltage- 1722V
Current- 50-120A

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USE OF CARBON-DI-OXIDE – Carbon-di-oxide is mainly used
as shielding gas which is why the process is also known as carbon-di-
oxide welding.
This gas is suitable for use with many brands of flux-cored wire.
Generally produces more spatter and particulate fume.
USE OF FLUX CORED WIRE - For many years the industry has
wanted a semi-automatic arc welding process with continuously fed wire
without exterior coating and with a higher deposition rate than that of
solid wire, known from the MAG welding process.If in addition a higher
safety against welding errors could be obtained, so such a semi-automatic
process could be used for welding in thicker dimensions, where
traditionally electrode were used.
USE OF HEATER- Heater is placed at the side of knob of cylinder t
avoid the formation of water particles.
To the continuous flow of gases through the pipe, lowering the
temperature allows the formation of water particle which produces hurdle
in the flow of gases, which causes welding defects.
 ADVANTAGES-
These are the following advantages of manual arc gas welding –
a) The method is financially attractive due to a high welding
speed and because a long arc time can be maintained as there
is no frequent changing of electrode rods.
b) The method provides the opportunity for rational welding of
materials which are difficult to weld.
c) Welding is possible in all possiblepositions.
(but here in SIL we use the vertical direction to weld the
workpiece)
d) The risk is serious welding errors is reduced compared to
welding with solid wire.
e) Usually only little after treatment of the weld is necessary.

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 APPLICATIONS-
MAG welding is usually used with –
a) Aluminium
b) Ordinary mild steel
c) Stainless steel
d) Copperand copperalloys
In addition to the above metal this method is suited for
magnesium, nickel and a number of other metal and metal
alloys.
 RESULT- Hence, the following parts have been welded with the
housing with the manual metal arc welding.

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STEP-2
MACHINE SHOP (LINE – 08)
TERMINOLOGIES USED-
1) FACING-
A single-point turning toolmoves radially, along the end of the
workpiece, removing a thin layer of material to provide a smooth flat
surface. The depth of the face, typically very small, may be machined in a
single pass or may be reached by machining at a small axial depth of cut
and making multiple passes.
ADVANTAGES-
d) After performing facing, the surface becomes smoothand well
finished.
e) Short lead time.
f) Very good tolerances
DISADVANTAGES-
d) Limited to rotational parts.
e) Parts may require several operation and machines.
f) High equipment cost.
g) Significant toolwear.
APPLICATION-
b) Machine components, shafts, engine components.

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2) BORING - Boring is the process ofproducing circular internal
profile on a hole made by drilling or another process.It uses single point
cutting toolcalled a boring bar. In boring, the boring bas can be rotated,
or the workpart can be rotated. Machine tolls which rotate the boring bar
against a stationary workpiece are boring machine.
Boring can accomplished on a turning machine with a stationary boring
bar positioned in the toolpostand rotating workpiece held in the lathe
chuck.
ADVANTAGES- The following are the advantages of the boring-

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d) All material compatible
e) Very good tolerance.
f) Low cost.
DISADVANTAGES- The following are the disadvantages of the boring
operation-
c) The material at the bottom of the hole is disturbed by heavy tool.
d) Limited tooling design.
APPLICATIONS-
c) Widely used for manufacturing of the machine components and engine
shafts.
d) Used in manufacturing of axle housing of various vehicle.
3) GRINDING- Grinding is an abrasive machining process that uses a
grinding wheel as the cutting tool.
Grinding practice is a large and diverse area of manufacturing and tool
making. It can producevery fine finished and very accurate dimensions;
yet in mass productioncontexts it can also rough out large volumes of
metal quite rapidly. It is usually better suited to the machining of very
hard materials that is regular machining.
LUBRICATIONS AND USES -The use of fluids in a grinding
process is necessary to cooland lubricate the wheel and workpieces as
well as remove the chips produced in the grinding process. Themost
common grinding fluids are water soluble chemical fluids, water soluble

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oils, synthetic oil and petroleum based oils etc. It is imperative that the
fluids be applied directly to the cutting area to prevent the fluid being
blown away from the piece due to rapid rotation of the wheel.
WORK
MATERIAL
CUTTING
FLUID
APPLICATIONS
Aluminium Light duty oil Flood
Brass Light duty oil Flood
Cast iron Heavy duty
emulsified oil, light
duty chemical oil,
synthetic oil
Flood
Mild steel Heavy duty water
soluble oil
Flood
Stainless steel Heavy duty
emulsified oil, heavy
duty chemical oil,
synthetic oil
Flood
Plastics Water soluble oil,
dry, heavy duty
emulsified oil, dry,
light duty chemical
Flood

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oil, synthetic oil
4) CHAMFERING- A chamfer is a transition edge between two vertices
of an object. It can also be known as a bevel but connotes more often
cutting and more often 45 degrees. If the un-chamfered intersection of the
adjoining faces would otherwise form right angle.
“chamfer” is a term commonly used in the mechanical and
manufacturing engineering.
ADVANTAGES-
The following are the advantages of the chamfering operation-
a) Easy to assemble.
b) Flexible adjustment to the cross section.
c) Chamfers can be machined inside and outside.
DISADVANTAGES- Following are the disadvantages of the
chamfering operation-
a) Greater accuracy and precision required.
b) Skilled labours are required for this operation.
c) Limited tooling design.
APPLICATIONS-

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a) Chamfering is widely used in manufacturing for axle housing.
b) Used in the architech engineering.
5) TURNING- This operation is one of the most basic machining
processes.That is, the part is rotated while a single point cutting tool is
moved parallel to the axis of rotation. Turning can be done on the
external surface of the part as well as internally. The starting material is
generally a workpiece generated by other processes suchas casting,
forging, extrusion, or drawing.
Turning can be done manually, in a traditional form of lathe, which requires
continuous supervision by the operator, or by using an automated lathe which
does not..
ADVANTAGES-
d) All materials compatible.
e) Very good tolerances.
f) Short lead time.
DISADVANTAGES-
f) Limited to rotational parts.
g) High equipment cost.
h) Significant toolwear.
i) Large amount of scrap.

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j) Part may require several operation and machines.
APPLICATIONS-
b) Machine components, shafts, engine components.
6) MILLING- Milling is the m machining process ofusing rotary cutters
to remove material from a workpiece advancing on a direction at an angle
with the axis of the tool. It covers a wide variety of different operation
and machines, on scales from small individual parts to large, heavy-duty
gang milling operation.
PROCESS-Milling is a cutting process that uses a milling cutter to
remove material from the surface of a workpiece. The milling cutter is a
rotary cutting tool, often with multiple cutting points. As opposedto
drilling, where the tool is advanced along its rotation axis, the cutter in
milling is usually moved perpendicular to its axis so that cutting occurs
on the circumference of the cutter. As the milling cutter enters the
workpiece, the cutting edge of the toolrepeatedly cut into and exit from
the material. The cutting action is shear deformation; material is pushed
off the workpiece in tiny clumps that hang together to a greater or lesser
extent to form chips.
There are two major classes of milling process-
a) Face milling
b) Peripheral milling

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OPERATION SHEET
SHEET NUMBER- 01
MODEL NAME- VIKRAM 410P
FROM THE STOCK- Welded assembly
PART NAME- Axial housing assembly RH
PART NUMBER- 43.64.2100
OPERATION NUMBER- 50
OPERATION- face and finish bore cavity ǿ82, chamfer opposite
. end, face total length 690
MACHINE- S.P.M
MACHINE NUMBER- 5619
LINE NUMBER- 8
DATA FOR
MACHINING
UNIT-1
2*30°
UNIT-2
ǿ82
UNIT-2
ǿ116
Rpm OF 700 320 320
Rpm OF - - -
Cutting speed in m/min 72 82 117
travel of (in mm) 10 10 21
Feed in mm/min 35 16 24
Feed in mm/rev 0.05 0.05 0.075
Depth of cut in mm - - -
Setting time in sec. - - -
OP. time in sec. 20 20 90
F/F time in sec. 115 115 115
STD. time in sec. - - -
% efficiency - - -
m/c setting time/batch - - -

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OPERATION SHEET
FROM THE STOCK-Sub assembly
OPERATION- Remove the face burres from the outer profile.
MACHINE- Pneumatic hand tool
0LINE NUMBER- 8

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OPERATION SHEET
SHEET NUMBER- 01
MOD0EL NAME- VIKRAM 410P
OPERATION- Copy turn as shown in the sketch
MACHINE- Russian copying lathe
LINE NUMBER- 8
DATA FOR MACHINING FACE TURN
Rpm OF 750 750
Rpm OF - -
Cutting speed in m/min 90 90
travel of (in mm) 32 102
Feed in mm/min - -
Feed in mm/rev 0.15 0.25
Depth of cut in mm - -
Setting time in sec. 15 15
OP. time in sec. 17 32
F/F time in sec. 68 68
STD. time in sec. - -
% efficiency - -
m/c setting time/batch - -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Copy turn as shown in the sketch
MACHINE- Russian copying lathe
LINE NUMBER- 8
DATA FOR MACHINING FACE TURN
Rpm OF 750 750
Rpm OF - -
Cutting speed in m/min 90 90
travel of (in mm) TOOL 32 100
Feed in mm/min - -
Feed in mm/rev 0.15 0.25
Depth of cut in mm - -
Setting time in sec. - 10
OP. time in sec. 17 32
F/F time in sec. 68 68
STD. time in sec. - -
% efficiency - -
m/c setting time/batch - -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Grind ǿ30 (-0.007)(-0.020)
MACHINE- MMT K130/800P cylindrical grinding machine
LINE NUMBER- 4
DATA FOR MACHINING
Rpm OF wheel 2500
Rpm OF job 270
Cutting speed in m/min 31.30
travel of (in mm) -
Feed in mm/min work -
Feed in mm/rev 0.003
Depth of cut in mm -
Setting time in sec. 10
OP. time in sec. 40
F/F time in sec. 50
STD. time in sec. -
% efficiency -
m/c setting time/batch -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Grind ǿ37 (+0)(-0.035)
LINE NUMBER- 4
DATA FOR MACHINING
Rpm OF wheel 2500
Rpm OF job 270
travel of (in mm) -
OP. time in sec. 20
F/F time in sec. 30
STD. time in sec. -
% efficiency -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Grind chamfer 1*30°
LINE NUMBER- 4
DATA FOR MACHINING
Rpm OF wheel 2500
Rpm OF job 270
travel of (in mm) -
OP. time in sec. 15
F/F time in sec. 25
STD. time in sec. -
% efficiency -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Lap ǿ37 (+0)(-0.039)
MACHINE- Innocenti lathe with lapping attachment
MACHINE NUMBER- 281
LINE NUMBER- 4
DATA FOR MACHINING
Rpm OF wheel -
Rpm OF job 270
travel of (in mm) -
Feed in mm/min work 2500
Feed in mm/rev -
OP. time in sec. 45
F/F time in sec. 60
STD. time in sec. -
% efficiency -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Roll thread M 30*1.5 6h
MACHINE- “Magnaghi” thread rolling machine
LINE NUMBER- 8
DATA FOR MACHINING
Rpm OF roller 25
Rpm OF job -
Cutting speed in m/min -
travel of (in mm) -
Feed in mm/rev -
OP. time in sec. 15
F/F time in sec. 25
STD. time in sec. -
% efficiency -

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OPERATION SHEET
SHEET NUMBER- 01
OPERATION- Mill slot 51 (+0.075)(-0)
MACHINE- Horizontal milling machine
LINE NUMBER- 8
DATA FOR MACHINING
Rpm OF cutter 100
Rpm OF job -
Cutting speed in m/min 19
travel of (in mm) tool 25
Feed in mm/min work 70
Feed in mm/rev 0.7
Depth of cut in mm 2.6
OP. time in sec. 21
F/F time in sec. 46
STD. time in sec. -
% efficiency -
NOTE- Two pieces are taken at a time only.

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STEP – 3
WELDING SHOP
 OBJECTIVE- To weld the buffer bracket with the housing with the help
of manual arc welding process.
 MATERIALS USED- Electrode, machined productfrom line-8, buffer
bracket.
 MACHINARY USED- Manual arc welding machine, safety guards.
 USE OF BUFFER BRACKET-
Buffer bracket is welded with the axle housing becausesometimes due to
large fluctuation of vehicle due to heavy load or irregular drive surface,
the leaf spring becomes straight , so to avoid further bending of the spring
to the maximum expansion; it is applied.
Due to this, is gives a small clearance to the leaf spring and does not
allows the bending of spring more than its maximum bending strength.
 RESULT- Hence, the buffer bracket has been welded with the ax;e
housing and ready for further manufacturing.

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STEP-4
PAINT SHOP
After the complete welding and machining process,further the workpiece is
moved to the paint shop for further finishing of the product.
But before the painting specimen is cleaned . Cleaning is done by passing the
specimen through different number of chemical tanks.
PURPOSE OF CLEANING BEFORE PAINTING-
Cleaning is done before painting in order to remove the impurities from the
workpiece which is attached to the surface during various manufacturing
process. Also it allows paint to stick properly on the work surface, which further
increases the life of the workpiece and it helps the work to get free from rust
and various further defects.
STEPS FOR CLEANING IN PHOSPHATING PLANT-
The workpiece is passed through various number of tanks followed by water
tanks, which allows that the result of one chemical does not affect the result of
the other following chemical tanks.
Therefore, below are following arrangement of the tanks for the complete
cleaning process or
a) Degreasing tank; followed by 2 water tanks.
b) De-rusting tank; followed by 2 water tanks.
c) Activation tank;
d) Phosphating tank; followed by 2 water tanks.
e) Passivationtank
f) Dry off oven
 DEGREASING-
TEMPERATURE- 40-50°C

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Solvent degreasing is a process used to prepare a part for further operations such
as electroplating or painting.
It is a process in which a cleaning agent is applied directly to the surface by
spraying, bushing, or wiping. This process removes oil, grease, dirt, loose
particles and any other contaminants that may exist on the material.
a) SPRAYING;the most common cold solvent operation, this is usually
small maintenance degreasers using a petroleum or mineral solvent.
b) IMMERSION;the part is immersed in a tank of solvent and usually
agitated like a washing machine for clothes to get all of the contaminant
off. Soaking is typically the most common process.The material is left to
soak until all the dirt are removed from the surface.
DESIGN CONSIDERATIONS-
BENEFITS –
a) The emissions are reduced when compared with vapor degreasing
operations.
b) Liquid solvent are safer to deal with than vapor degreasing agents.
c) Not as much venting is required, so it is easier to quickly set up a small
degreasing operation.
CHALLENGES-
a) There is a high danger of fire when using petroleum and mineral solvents.
b) The emission from this type of operation, although less than those of
other operations, are still considerable, and solvent degreasing has an
environment impact.
c) Solvent are difficult to disposeof, and there are many government
regulation on them.
 DERUSTING-
CHEMICAL USED- phosphoric acid.
TEMPERATURE- 40-50°C

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This derusting process removes only the rust from the parts- all other
exposed metal along with their tolerance will not be affected. Afterwards,
all types of rust inhibitors are applied to the parts for rust protection.
The total derusting process uses no harsh acids and leaves no powder
residue on the parts. Once again, all shapes and sizes are accommodated
packaged to the customer’s specifications. All services are performed
with quick turn around and utilizing environmentally friendly methods.
ADVANTAGES OF PHOSPHORIC ACID-
The following are the advantages of using phosphoric acid-
a) It will provide corrosionresistance of phosphate coating.
b) No toxic fumes.
c) No handling hazards.
d) Produces coating of low thickness but higher weights is ideal for
better paint adhesion.
 ACTIVATION PROCESS-
The activation tank is used widely for the cleaning purpose. Activation
tank helps material to activate the workpiece for the further processing.
Which activates the surface of the workpiece and helps to get ready for
the painting purpose.
This type of cleaning process is not followed by water tanks because if
water tanks is used it will again wash the surface will which reduce the
affect of activating chemicals.
 PHOSPHATING PROCESS-
Phosphatecoating are used on steel parts for corrosionresistance,
lubricity, or as a foundation for subsequent coating or painting.
It serves as a conversion coating in which dilute solution of phosphoric
acid and phosphate salts is applied via spraying or immersion and
chemically reacts with the surface of the part being coated to form a layer
of insoluble, crystalline phosphate.

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PROCESS-
The application of phosphatecoating makes use of phosphoric acid and
takes advantages of the low solubility of phosphates in medium or high
pH solutions. Iron, zinc or manganese phosphate salts are dissolved in the
solution of phosphoric acid. When steel or iron parts are placed in the
phosphoric acid, a classic acid and metal reaction takes place which
locally depletes the hydronium ions, raising the pH, and causing the
dissolved salt to fall out of solution and be precipitated on the surface.
The acid and metal reaction also creates iron phosphatelocally which
may also be deposited.
The acid and metal reaction also generates hydrogen gas in the form of
tiny bubbles that adhere to the surface of the metal. These prevent the
acid from reacting the m0etal surface and slows down the reaction.
USES-
Phosphatecoating are often used to provide corrosion resistance,
however, phosphatecoating and their own do not provide this because the
coating is porous.
 PASSIVATION PROCESS-
CHEMICAL USED- Chromic acid
This process is just oppositeof activation process.
This process is imposed on the work material to avoid the reaction of the
work material from the external environment.
Hence it deactivate the surface of the work material and helps the surface
to get ready for the painting process.
 DRYING PROCESS-
TEMPERATURE- 120±5 °C

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In this process the work material is kept in the DRY OFF OVEN, which
helps the surface to get dry, because if the surface is not dried the paint
which is being applied on the surface will not get attached properly.
Hence it is applied for properadhesion of the paint.
 PAINTING PROCESS-
MACHINERY USED-
a) Hydraulic spraying machine.
b) Hand gun.
Electrostatic spraying machine, is a type of machinery which is widely
used in industries for the painting process.
The workpiece which is to be painted is held with the help of jack, and moves
on the relay line. As the workpiece comes near to the spraying machine the
paint get pressure and exit out from the machine.
Stem size of this machine is changed according to the length and width of the
workpiece.
HAND GUN, this is used for the final finishing of the workpiece. Sometimes,
during the painting via hydraulic spraying machine some parts of the workpiece
does not get painted. Therefore hand gun is used manually by staff for the final
finishing of the workpiece.
Hence, the productis ready for the further assembly process.

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STEP-5
VEHICLE ASSEMBLY
Following are the steps which is been followed for the final assembly of the
axle housing-
a) Axle pin is attached to the back plate.
b) Drum is attached on the back plate.
c) Further, two chuck nuts is fitted for the locking of the drum and back
plate with housing.
d) One chuck nut is placed front then locked; then another chuck nut is
placed oppositeto it and also get locked.
This allows the interlocking of the both nuts which gives proper holding
of drum and back plate.
e) Hence, another end is connected to the differential system.
f) Also, leaf spring is connected to the one end where drum is connected.
No. of leaves=7 in RHM
No. of leaves=9 in RHD
g) Leaf spring is supported with the help of U-bolt for further supportof the
leaf spring.
h) Buffer plate is attached to exert jerk when leaf spring becomes straight, it
avoid jerk to luggage and passengers.
i) Therefore, the final assembly of the axle housing is completed and it is
ready for further assembly.

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REFERENCES
1) Automotive Mechanics – by William H. Crouse & Donald L.
Anglin
2) Theory Of Machines- by S.S.Ratna.
3) Internal Combustion Engines- by V.Ganeshan
4) Through Google (www.google.com)
5) Through Wikipedia(www.wikipedia.com)

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