1. A SUMMER TRAINING REPORT
ON
“WORKSHOP PRACTICES & RELATED MECHANICAL ACTIVITIES IN CENTRAL WORKSHOPS, JAYANT”
By-: kundan giri
MIET ,meerut
2. ACKNOWLEDGEMENT
My acknowledgement deeply thanks the co-operation received from all the employees of Northern
Coalfields Limited, Singrauli as a whole for providing me the opportunity to learn from them their
systematic approach of accomplishing the work. I also convey my gratitude to the employees
specially the Central workshop for intending all the help I needed and the congenial working
environment they provided me during my project, they were so helpful that I never felt that I am
working with the persons senior to me age wise as well as experience wise. With their guidance co-
operation and best wishes it would have been possible for me to complete my training and report
satisfactorily. I express my deep sense of gratitude of Mr. Poorna Kolagani of NCL for his constant
supervision during the entire project work. I am truly grateful to all the shop Managers who gave
me vital information related to my project work.
I would also like to thank to my all family members whose morale support helped me to complete
my project successfully. Lastly, a big thanks to all those who helped me sparing time even through
their busy schedule and for being kind enough to help me whenever needed them.
Regards,
Kundan Giri
Mechanical engg.
MIET, Meerut
3. TABLE OF CONTENTS
ON “WORKSHOP PRACTICES & RELATED MECHANICAL ACTIVITIES IN CENTRAL
WORKSHOPS,JAYANT” ........................................................................................................................................................ 1
ACKNOWLEDGEMENT .......................................................................................................................................................... 2
INTRODUCTION ....................................................................................................................................................................... 4
Machine shop ............................................................................................................................................................................ 6
Welding shop........................................................................................................................................................................... 11
Transmission shop ................................................................................................................................................................ 22
Engine shop.............................................................................................................................................................................. 26
4. INTRODUCTION
Mission
THE MISSION OF COAL INDIA IS TO PRODUCE AND MARKET THE
PLANNED QUANTITY OF COAL AND COAL PRODUCTS
EFFECIENTLY AND ECONOMICALLY WITH DUE REGARDS
TO SAFETY, CONSERVATION QUALITY AND ENVIRONMENT
Northern Coalfields Limited was formed in April 1986 as a subsidiary company of Coal India
Limited. Its headquarter is located at Singrauli, Distt. Sidhi (M.P.). Singrauli is connected by
road with Varanasi (220 Km.) – a holy city on the banks of river Ganga, and Rewa (206
Km.) – the state of white tigers and Sidhi (100 Km.) – district headquarter town of Madhya
Pradesh. The nearest railway station is Singrauli located on the Katni-Chopan branch line
running parallel to the northern boundary of the Coalfield. The nearest railway station for
reaching directly to Delhi and Kolkata is Renukoot that is located on the Garhwa-Chopan
rail-line. Nearest (private) airstrip is at Muirpur (60 Km.).
The area of Singrauli Coalfields is about 2202 Sq.Km. The coalfield can be divided into two
basins, viz. Moher sub-basin (312 Sq.Km.) and Singrauli Main basin (1890 Sq.Km.). Major
part of the Moher sub-basin lies in the Sidhi district of Madhya Pradesh and a small part lies
in the Sonebhadra district of Uttar Pradesh. Singrauli main basin lies in the western part of
the coalfield and is largely unexplored. The present coal mining activities and future blocks
are concentrated in Moher sub-basin.
The exploration carried out by GSI/NCDC/CMPDI has proved abundant resource of power
grade coal in the area. This in conjunction with easy water resource from Govind Ballabh
Pant Sagar makes this region an ideal location for high capacity pithead power plants. The
coal supplies from NCL has made it possible to produce about 10515 MW of electricity from
pithead power plants of National Thermal Power Corporation (NTPC), Uttar Pradesh Rajya
Vidyut Utpadan Nigam Ltd (UPRVUNL) and Renupower division of M/s. Hindalco Industries.
The region is now called the "power capital of India". The ultimate capacity of power
generation of these power plants is 13295 MW and NCL is fully prepared to meet the
increased demand of coal for the purpose. In addition, NCL is also supplying coal to power
plants of Rajasthan Rajya Vidyut Utpadan Nigam Ltd, Delhi Vidyut Board (DVB) and
Hariyana State Electricity Board.
NCL produces coal through mechanised opencast mines but its commitments towards
environmental protection is total. It is one of very few companies engaged in mining
activities, which has got ISO –14001 Certification for its environmental systems.
5. NCL, through its community development programmes, has significantly contributed
towards improvement and development of the area. It is helping local tribal, non-tribal and
project-affected persons in overall improvement of quality of their life through self-
employments schemes, imparting education and providing health care.
Salient features
TOTAL AREA 2202 Sq.Km.
AREA OF MOHER BASIN 312 Sq.Km.
AREA OF MAIN BASIN 1890 Sq.Km.
ESTIMATED RESERVES OF MOHER BASIN
8.31 Billion Tonnes
As on 31.03.07
BALANCE MINEABLE RESERVES OF MOHER BASIN (up to
2.68 Billion Tonnes
300 meter depth) As on 31.03.07
LIFE OF COALFIELD AT SCHEDULED RATE OF
37 YRS.
PRODUCTION.
JHINGURDA 130-138 m D-E
PUREWA TOP 9 m D-E
COAL SEAMS IN MOHER BASIN, THICKNESS & GRADE
PUREWA BOTTOM 12 m C-D
TURRA 20 m C-E
GRADIENT 2 to 5 DEGREES
Note: Jhingurda seam is the Thickest Coal Seam of India
6. WELDING SHOP
-UNDER MR. G.S VISWAKARMA,
MR. S.P DWIVEDI
MR. SAMIM
M R . S A TR U D HA N
(FROM 21ST JUNE 2011 TO 27TH JUNE 2011)
THINGS COVERED DURING WELDING SHOP TRAINING
PERIOD:-
Safety while welding
Types of safeties
Types of welding
Welding equipments
Welding techniques
Welding defects and distortions
Prevention of defects
Types of welding starts
Different types of welding machines
Electric arc welding
Submerged arc welding
Gas welding and gas cutting
Flux(metallurgy)
Shielding gas FIGURE 1: WELDING SAFTEY
EQUIPMENTS BEING PROVIDED AT
Welding joints CWS JAYANT, NCL
ARC WELDING
Gas metal arc welding
Arc welding is a type of welding that uses a welding power supply to create an electric arc between
an electrode and the base material to melt the metals at the welding point. They can use either
direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The
welding region is usually protected by some type of shielding gas, vapor, and/or slag. Power
supplies Engine driven welder capable of AC/DC welding. To supply the electrical energy necessary
for arc welding processes, a number of different power supplies can be used. The most common
classification is constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current is related to the
amount of heat input. Constant current power supplies are most often used for manual welding
processes such as gas tungsten arc welding and shielded metal arc welding, because they maintain
a relatively constant current even as the voltage varies. This is important because in manual
7. welding, it can be difficult to hold the electrode perfectly steady, and as a result, the arc length and
thus voltage tend to fluctuate. Constant voltage power supplies
hold the voltage constant and vary the current, and as a result,
are most often used for automated welding processes such as
gas metal arc welding, flux cored arc welding, and submerged
arc welding. In these processes, arc length is kept constant,
since any fluctuation in the distance between the wire and the
base material is quickly rectified by a large change in current.
For example, if the wire and the base material get too close, the
current will rapidly increase, which in turn causes the heat to
increase and the tip of the wire to melt, returning it to its
original separation distance. The direction of current used in
arc welding also plays an important role in welding.
Consumable electrode processes such as shielded metal arc
welding and gas metal arc welding generally use direct current,
but the electrode can be charged either positively or
negatively. In welding, the positively charged anode will have a
greater heat concentration and, as a result, changing the
polarity of the electrode has an impact on weld properties. If
the electrode is positively charged, it will melt more quickly,
increasing weld penetration and welding speed. Alternatively,
FIGURE 2:ENGINE DRIVEN WELDER
a negatively charged electrode results in more shallow welds. CAPABLE OF AC/DC WELDING.
Non-consumable electrode processes, such as gas tungsten arc
welding, can use either type of direct current (DC), as well as alternating current (AC). With direct
current however, because the electrode only creates the arc and does not provide filler material, a
positively charged electrode causes shallow welds, while a negatively charged electrode makes
deeper welds. Alternating current rapidly
moves between these two, resulting in
medium-penetration welds. One disadvantage
of AC, the fact that the arc must be re-ignited
after every zero crossing, has been addressed
with the invention of special power units that
produce a square wave pattern instead of the
normal sine wave, eliminating low-voltage
time after the zero crossings and minimizing
the effects of the problem. Home and hobby
power supplies Home and hobby arc welders
for occasional light duty (under 0.25
FIGURE 3: A DIESEL POWERED WELDING
in/unknown operator: u'strong' mm plate)
GENERATOR (THE ELECTRIC GENERATOR IS ON
THE LEFT) repair and construction are available from $100
and up as of 2011. In the $100 to $200 range,
many choices are available in welding power supplies such as output current at a given duty cycle,
120 volts (domestic) or 220 V AC, and differing input currents. At these low prices, any positive
factor typically weakens another important factor. One seller offers this specification: "Duty Cycle:
45% @ 60 amps, 25% @ 80 amps," for their 120 volts, 20 A input, "90 Amp Flux Wire Welder". Duty
cycle is a welding equipment specification which defines the number of minutes, within a 10 minute
period, during which a given arc welder can safely be used. For example, an 80 A welder with a 60%
8. duty cycle must be "rested" for at least 4 minutes after 6 minutes of continuous welding.[5] Failure
to observe duty cycle limitations could damage the welder. Commercial- or professional-grade
welders typically have a 100% duty cycle.
SAFETY ISSUES
Welding can be a dangerous and unhealthy practice without the proper precautions; however, with
the use of new technology and proper protection the risks of injury or death associated with
welding can be greatly reduced.
Heat and sparks
Because many common welding procedures involve an
open electric arc or flame, the risk of burns from heat
and sparks is significant. To prevent them, welders wear
protective clothing in the form of heavy leather gloves
and protective long sleeve jackets to avoid exposure to
extreme heat, flames, and sparks.
Eye damage
Exposure to the brightness of the weld area leads to a
condition called arc eye in which ultraviolet light causes
inflammation of the cornea and can burn the retinas of
the eyes. Welding goggles and helmets with dark face
plates - much darker than those in sunglasses or oxy-fuel
goggles - are worn to prevent this exposure. In recent
years, new helmet models have been produced featuring
a face plate that automatically self-darkens FIGURE 4: AUTO DARKENING WELDING
electronically. To protect bystanders, transparent HOOD WITH 90×110 MM CARTRIDGE AND
welding curtains often surround the welding area. These 3.78×1.85 IN VIEWING AREA
curtains, made of a polyvinyl chloride plastic film, shield
nearby workers from exposure to the UV light from the electric arc.
Inhaled matter
Welders are also often exposed to dangerous gases and particulate matter. Processes like flux-cored
arc welding and shielded metal arc welding produce smoke containing particles of various types of
oxides. The size of the particles in question tends to influence the toxicity of the fumes, with smaller
particles presenting a greater danger. Additionally, many processes produce various gases (most
commonly carbon dioxide and ozone, but others as well) that can prove dangerous if ventilation is
inadequate. Furthermore, the use of compressed gases and flames in many welding processes pose
an explosion and fire risk;some common precautions include limiting the amount of oxygen in the
air and keeping combustible materials awayfrom the workplace.
Interference with pacemakers
Certain welding machines which use a high frequency AC current component have been found to
affect pacemaker operation when within 2 meters of the power unit and 1 meter of the weld site.
9. ELECTRODE
An electrode is an electrical conductor used to make
contact with a non-metallic part of a circuit (e.g. a
semiconductor, an electrolyte or a vacuum). The word
was coined by the scientist Michael Faraday from the
Greek words elektron (meaning amber, from which the
word electricity is derived) and hodos, away.
Anode and cathode in electrochemical cells
An electrode in an electrochemical cell is referred to as
either an anode or a cathode (words that were also coined
by Faraday).The anode is now defined as the electrode at
which electrons leave the cell and oxidation occurs, and FIGURE 5: ELECTRODES USED IN ARC
the cathode as the electrode at which electrons enter the WELDING
cell and reduction occurs. Each electrode may become
either the anode or the cathode depending on the direction of current through the cell. A bipolar
electrode is an electrode that functions as the anode of one cell and the cathode of another cell.
Primary cell
A primary cell is a special type of electrochemical cell in which the reaction cannot be reversed, and
the identities of the anode and cathode are therefore fixed. The anode is always the negative
electrode. The cell can be discharged but not recharged.
Secondary cell
A secondary cell, for example a rechargeable battery, is one in which the chemical reactions are
reversible. When the cell is being charged, the anode becomes the positive (+) and the cathode the
negative (−) electrode. This is also the case in an electrolytic cell. When the cell is being discharged,
it behaves like a primary cell, with the anode as the negative and the cathode as the positive
electrode.
Other anodes and cathodes
In a vacuum tube or a semiconductor having polarity (diodes, electrolytic capacitors) the anode is
the positive (+) electrode and the cathode the negative (−). The electrons enter the device through
the cathode and exit the device through the anode. Many devices have other electrodes to control
operation, e.g., base, gate, control grid. In a three-electrode cell, a counter electrode, also called an
auxiliary electrode, is used only to make a connection to the electrolyte so that a current can be
applied to the working electrode. The counter electrode is usually made of an inert material, such as
a noble metal or graphite, to keep it from dissolving.
Welding electrodes
In arc welding an electrode is used to conduct current through a workpiece to fuse two pieces
together. Depending upon the process, the electrode is either consumable, in the case of gas metal
arc welding or shielded metal arc welding, or non-consumable, such as in gas tungsten arc welding.
For a direct current system the weld rod or stick may be a cathode for a filling type weld or an
10. anode for other welding processes. For an alternating current arc welder the welding electrode
would not be considered an anode or cathode.
Alternating current electrodes
For electrical systems which use alternating current the electrodes are the connections from the
circuitry to the object to be acted upon by the electric current but are not designated anode or
cathode since the direction of flow of the electrons changes periodically, usually many times per
second.
Uses
Electrodes are used to provide current through nonmetal objects to alter them in numerous ways
and to measure conductivity for numerous purposes.
Examples include:
• Electrodes for medical purposes, such as EEG, ECG, ECT, defibrillator
• Electrodes for electrophysiology techniques in biomedical research
• Electrodes for execution by the electric chair
• Electrodes for electroplating
• Electrodes for arc welding
• Electrodes for cathodic protection
• Electrodes for grounding
• Electrodes for chemical analysis using electrochemical methods
• Inert electrodes for electrolysis (made of platinum)
• Membrane electrode assembly
Chemically modified electrodes
Chemically modified electrodes are electrodes that have their surfaces chemically modified to
change the electrode's physical, chemical, electrochemical, optical, electrical, and transport
properties. These electrodes are used for advanced purposes in research and investigation.
SUBMERGED ARC WELDING
Submerged arc welding (SAW) is a common arc welding process. Originally developed by the Linde
- Union Carbide Company. It requires a non-continuously fed consumable solid or tubular (flux
cored) electrode. The molten weld and the arc zone are protected from atmospheric contamination
by being “submerged” under a blanket of granular fusible flux consisting of lime, silica, manganese
oxide, calcium fluoride, and other compounds. When molten, the flux becomes conductive, and
provides a current path between the electrode and the work. This thick layer of flux completely
covers the molten metal thus preventing spatter and sparks as well as suppressing the intense
ultraviolet radiation and fumes that are a part of the shielded metal arc welding (SMAW) process.
11. SAW is normally operated in the automatic or mechanized mode, however, semi-automatic (hand-
held) SAW guns with pressurized or gravity flux feed delivery are available. The process is normally
limited to the flat or horizontal-fillet welding positions (although horizontal groove position welds
have been done with a special arrangement to support the flux). Deposition rates approaching 100
lb/h (45 kg/h) have been reported — this compares to ~10 lb/h (5 kg/h) (max) for shielded metal
arc welding. Although
Currents ranging from
300 to 2000 A are
commonly utilized,[1]
currents of up to 5000 A
have also been used
(multiple arcs).
Single or multiple (2 to 5)
electrode wire variations
of the process exist. SAW
strip-cladding utilizes a
flat strip electrode (e.g. 60
mm wide x 0.5 mm thick).
DC or AC power can be
used, and combinations of
DC and AC are common on
multiple electrode
systems. Constant voltage
welding power supplies FIGURE 6: SUBMERGED ARC WELDING. THE WELDING HEAD MOVES FROM
are most commonly used; RIGHT TO LEFT. THE FLUX POWDER IS SUPPLIED BY THE HOPPER ON THE
LEFT HAND SIDE, THEN FOLLOW THREE FILLER WIRE GUNS AND FINALLY A
however, constant current VACUUM CLEANER.
systems in combination
with a voltage sensing
wire-feeder are available.
OXY-FUEL WELDING AND CUTTING
Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the U.S.)
and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals,
respectively. French engineers Edmond Fouché and Charles
Picard became the first to develop oxygen-acetylene welding
in 1903. Pure oxygen, instead of air (20% oxygen/80%
nitrogen), is used to increase the flame temperature to allow
localized melting of the workpiece material (e.g. steel) in a
room environment. A common propane/air flame burns at
about 3,630 °F (2,000 °C), a propane/oxygen flame burns at
about 4,530 °F (2,500 °C), and an acetylene/oxygen flame
burns at about 6,330 °F (3,500 °C).
Oxy-fuel is one of the oldest welding processes. Still used in
industry, in recent decades it has been less widely utilized in
industrial applications as other specifically devised
12. technologies have been adopted. It is still widely used for
welding pipes and tubes, as well as repair work. It is also
frequently well-suited, and favored, for fabricating some
types of metal-based artwork.
In oxy-fuel welding, a welding torch is used to weld metals.
Welding metal results when two pieces are heated to a
temperature that produces a shared pool of molten metal.
The molten pool is generally supplied with additional metal
called filler. Filler material depends upon the metals to be
welded.
In oxy-fuel cutting, a torch is used to heat metal to its kindling temperature. A stream of oxygen is
then trained on the metal, burning it into a metal oxide that flows out of the kerf as slag.
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered
oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel cutting requires two
isolated supplies, fuel and oxygen). Most metals cannot be melted with a single-tank torch. As such,
single-tank torches are typically used only for soldering and brazing, rather than welding.
13. MACHINE SHOP
-UNDER SURINDER SINGH
( F R O M 2 8 T H J U N E 2 0 1 1 TO 4 T H J U N E 2 0 1 1 )
MACHINES AVAILABLE IN THE MACHINE SHOP
1. To 23. Lathes in different sizes
24. SB CNC
25. NH CNC
26. BVS 25/50
27. Milling (total 6 machines,m1 to m6)
28. Horizontal boring machines
29. Radial drill (3)
30. Slotters (2)
31. Shapers (3)
32. Power grinders (4)
33. Surface grinders
34. Center less grinder
35. Tool post grinder
36. Power hacksaw
37. Band saw
38. Gear hobbins
39. Circular saw
40. EOT cranes (10 ton and 5 ton capacities)
41. Planomiller
LATHE
One of the most important machine tools in the metalworking industry is the lathe. A lathe operates
on the principle of a rotating workpiece and a fixed cutting tool. The cutting tool is feed into the
workpiece, which rotates about its own Z-axis, causing the workpiece to be formed to the desired
shape. The lathes in the Student Shop are commonly referred to as “engine lathes”. Thisis the most
popular type of lathe in industry because of its versatility and ease ofoperation. Some of the more
frequently performed operations on the
engine lathe are: turning cylindrical
surfaces, facing flat surfaces, drilling and
boring holes, and cutting internal or external
threads. Although relatively simple, these
few operations provide a wide range of
manufacturing ability. Lathes are classified
according to the maximum diameter, (know
as the “swing”), and the maximum length of
the workpiece that can be handled by the
lathe. Another important characteristic of
any lathe is the maximum horsepower that
can be supplied to rotate the workpiece. A
new way lathes are being classified today is by their controls, manual, computer-numerically-
14. controlled, (commonly called CNC), and the latest referred to as hybrid lathes. Hybrid lathes are a
cross between the standard manually operated lathe and the computer operated lathe, CNC.
Lathe Construction
There are four main groups of components that comprise the basis for all engine lathes. These
consist of the: bed, headstock, tailstock, and the carriage. Please refer to figure for clarity.
The bed is the foundation of the engine lathe. The bed is a heavy, rugged casting made to support
the working parts of the lathe. The size and mass of the bed gives the rigidity necessary for accurate
engineering tolerances required in manufacturing today. On top of the bed are machined ways that
guide and align the carriage and tailstock, as they are move from one end of the lathe to the other.
The headstock is clamped atop the bed at the left-hand end of the lathe. The headstock contains the
motor that drives the spindle through a series of gears. The workpiece is mounted to the spindle
through means of a chuck, faceplate, or collet. Since the headstock contains the motor and drive
gears, the speed or RPM at which the spindle rotates is also controlled here. The headstock also
contains the power feed adjustments, which are the controls for the rate at which the carriage
moves when the power feed lever in engaged. The carriage assembly moves lengthwise,
(longitudinally), along the ways between the headstock and the tailstock. The carriage is composed
of the cross slide, compound rest, saddle, and apron. The saddle is an H shaped casting mounted on
top of the ways, and supports the cross slide and compound rest. The apron is fastened to the
saddle, and houses the automatic feed mechanisms. The cross slide is mounted on top of the saddle,
and can be moved either manually or automatically across the longitudinal axis (Z-axis) of the
spindle. This provides the lathe’s X-axis, which is the diameter the workpiece is machined to. The
compound rest holds the tool post, which supports the cutting tool. Mounted on top of the cross
slide, the compound rest can be swiveled to any angle in the horizontal plane. This is useful when
cutting angles and short tapers on the workpiece.
Procedures
Proficiency in lathe operations involves more than simply “turning” metal. Quality work can be
produced on the lathe if the job is planned in advance. There are two main categories of procedures
to be followed when machining parts on a lathe: the preliminary operations, and the machining
operations.
Preliminary Operations-
Cleaning- The first, (and last), procedure in any machining operation. Without clean equipment and
tools, the accuracy of the finished product diminishes quickly. The accuracy, durability, and
longevity of the equipment and tools depend on being kept clean. In today’s high tolerances in
engineering, cleanliness is critical.
Holding the workpiece- There are several types of holding devices used on the engine lathe. The
most common is the three-jaw chuck (see figure). This chuck permits all three jaws to work
simultaneously, automatically centering round or hexagonal shaped pieces. Each jaw only fits with
the particular groove in the exact chuck it was made for, so the jaws are not interchangeable
between chucks. The advantages of this type of chuck are that it is very versatile, quick set-up, large
range of sizes, and uniform holding pressure on the workpiece. The disadvantage is that is the least
accurate of the holding devices in the Student Shop. The three-jaw chuck only has an accuracy of
15. between +0.005” to +0.010”, depending upon its condition. The second type of chuck is the four-jaw
chuck, (see figure). This is also called the independent chuck because each of its jaws operates
independent of the other three. This permits odd shaped work to be held and centered about a
feature. The advantages are that it is versatile, provides a secure hold o the workpiece, large range
of sizes, and has extremely accurate centering method. The four-jaw chuck is accurate to +0.0005”.
The main disadvantage is the long process necessary to center the workpiece, requiring a high level
of in the use of a dial indicator. A third important holding device is the spring collet. This is a
popular style due to its ease of use and good accuracy. The spring collet will usually repeat within
+0.001”. Disadvantages to the spring collet are limitations to the size of each collet, (+0.005”),
restrictive to only round workpieces, and a maximum diameter of 1-1/16”. 3-Jaw Chuck 4-Jaw
Chuck Spring Collet
Tooling- Tools must be clamped securely to the tool post regardless of what type of tool is being
used. It is also recommended to have the cutting tool extended the least amount possible to reduce
torque and vibrations induced in the tool when cutting. The tools must be adjusted so that their
cutting edge is at the height of the exact center of the workpiece. This Defined as a line running
between the center of the headstock and tailstock spindles. Each lathe has a turning, facing and
parting tool as part of its tooling accessories.
Machine Controls- Many factors must be
considered when determining the correct speed,
(RPM), and feed rates. Some of these are:
1. Type of material being machined.
2. Desired finish to the workpiece.
3. Condition of the lathe.
4. Rigidity of the workpiece. Smaller diameters are
less rigid.
5. Shape and size of the workpiece.
6. Size and type of tooling being used.
Machining Operations
Once the set-up is complete, a quick check should
be made of the machine settings. Next, the work
should be checked that it is in the holding device
correctly. This is done with the machine OFF, FIGURE 7: A STEADY REST
manually rotate the chuck, seeing if there are any
interference points or possible inference points. Once this is complete, the machining operations
can being. There are usually two phase to machining, roughing and finishing. The roughing
operation is the process of removing the unwanted material to within about 1/32”, (about 0.030”),
of the finished dimension. Roughing speeds are approximately 80% of the finishing speeds.
Roughing feed rates are from 0.005” to 0.010”/revolution. Sizes and lengths should be check after
the roughing operation before going on to the finish operation. Finish operations are used to bring
the workpiece to the required size, length, shape, and surface finish. Depending upon the surface
16. finish desired, feed rates are generally between 0.001” to 0.005”/revolution. The main difference
between roughing and finishing cuts is the depth of cut. Depth of cut refers to the distance the
cutter has been fed, or advanced, into the workpiece surface. The depth of cut, like feed rates, varies
greatly with the machining conditions. Material, hardness, speed, and total material needed to be
removed all play a part in figuring the depth of cut amount. Roughing depth of cuts are greater, or
deeper than finishing depth of cuts, which are finer or shallower. All cuts, whether roughing or
finishing, should be made from right to left. Traveling towards the chuck as oppose to away from it
offers the greatest rigidity and therefore the greatest safety.
Safety;
The lathe can be a safe machine, but only if the student is aware of the hazards involved. In the
machine shop you must always keep your mind on your work in order toavoid accidents.
Distractions should be taken care of before machining is begun. Develop safe working habits in the
use of safety glasses, set-ups, and tools. The following rules must be observed when working on the
lathes in the Student Shop:
1. No attempt should be made to operate the lathe until you understand the proper procedures for
its use and have been checked out on it.
2. Dress appropriately. Remove all watches and jewelry. Safety glasses or goggles are a must.
3. Plan out your work thoroughly before starting.
4. Know where the location of the OFF switch is.
5. Be sure the work and holding device are firmly attached.
6. Turn the chuck by hand, with the lathe turned OFF, to be sure there is no danger of striking any
part of the lathe.
7. Always remove the chuck key from the chuck immediately after use, and before operating the
lathe. Make it a habit to never let go of the chuck key until it is out of the chuck and back in its
holder.
8. Keep the machine clear of tools. Tools must not be placed on the ways of the lathe.
9. Stop the lathe before making any measurements, adjustments, or cleaning.
10. Support all work solidly. Do not permit small diameter work to project too far from the chuck,
(over 3X’s the work’s diameter), without support.
12. If the work must be repositioned or removed from the lathe. Move the cutting tool clear of the
work to prevent any accidental injuries.
13. You should always be aware of the direction of travel and speed of the carriage before you
engage the automatic feed.
14. Chips are sharp. Do not attempt to remove them with your hand when they become “stringy”
and build up on the tool post or workpiece. Stop the machine and remove them with plies.
17. 15. Stop the lathe immediately if any odd noise or vibration develops while you are operating it. If
you cannot locate the source of the trouble, get help from the instructor. Under no circumstance
should the lathe be operated until the problem has been corrected.
16. Remove sharp edges and burrs from the work before removing it from the lathe.
17. Use care when cleaning the lathe. Chips sometimes get caught in recesses. Remove them with a
brush or short stick. Never use a floor brush to clean the machine. Use only a brush, compressed air,
or a rag.
SHAPER
Shaper with boring bar setup to allow cutting of internal features, such as keyways, or even shapes
that might otherwise be cut with wire EDM. A shaper is a type of machine tool that uses linear
relative motion between the workpiece and a single-point cutting tool to machine a linear toolpath.
Its cut is analogous to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding
axes of motion can yield helical toolpaths, as also done in helical planing.) A shaper is analogous to a
planer, but smaller, and with the cutter riding a ram that moves above a stationary workpiece,
rather than the entire workpiece moving beneath the cutter. The ram is moved back and forth
typically by a crank inside the column; hydraulically actuated shapers also exist.
Types
Shapers are mainly classified as higher, draw-cut, horizontal, universal, vertical, geared, crank,
hydraulic, contour and traveling head. The horizontal arrangement is the most common. Vertical
shapers are generally fitted with a rotary table to enable curved surfaces to be machined (same idea
as in helical planing). The vertical shaper is essentially the same thing as a slotter (slotting
machine), although technically a distinction can be made if one defines a true vertical shaper as a
machine whose slide can be moved from the vertical. A slotter is fixed in the vertical plane.
Small shapers have been successfully made to operate by hand power. As size increases, the mass of
the machine and its power requirements increase, and it becomes necessary to use a motor or other
supply of mechanical power. This motor drives a mechanical arrangement (using a pinion gear, bull
gear, and crank, or a chain over sprockets) or a hydraulic motor that supplies the necessary
movement via hydraulic cylinders.
PLANER (METALWORKING)
A planer is a type of metalworking machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of
a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion can yield
helical toolpaths; see "Helical planing" below.) A planer is analogous to a shaper, but larger, and
with the entire workpiece moving on a table beneath the cutter, instead of the cutter riding a ram
that moves above a stationary workpiece. The table is moved back and forth on the bed beneath the
cutting head either by mechanical means, such as a rack and pinion drive or a leadscrew, or by a
hydraulic cylinder.
Linear planing
The most common applications of planers and shapers are linear-toolpath ones, such as:
18. • Generating accurate flat surfaces. (While not as precise as grinding, a planer can remove a
tremendous amount of material in one pass with high accuracy.)
• Cutting slots (such as keyways).
• It is even possible to obviate wire EDM work in some cases. Starting from a drilled or cored hole, a
planer with a boring-bar type tool can cut internal features that don't lend themselves to milling or
boring (such as irregularly shaped holes with tight corners).
Helical planing
Although the archetypal toolpath of a planer is linear, helical toolpaths can be accomplished via
features that correlate the tool's linear advancement to simultaneous workpiece rotation (for
example, an indexing head with linkage to the main motion of the planer). To use today's
terminology, one can give the machine other axes in addition to the main axis. The helical planing
idea shares close analogy with both helical milling and single-point screw cutting. Although this
capability existed from almost the very beginning of planers (circa 1820), the machining of helical
features (other than screw threads themselves) remained a hand-filing affair in most machine
shops until the 1860s, and such hand-filing did not become rare until another several decades had
passed.
HORIZONTAL BORING MACHINE
A horizontal boring machine or horizontal boring mill is a machine tool which bores holes in a
horizontal direction. There are three main types — table, planer and floor. The table type is the most
common and, as it is the most versatile, it is also known as the universal type. A horizontal boring
machine has its work spindle parallel to the ground and work table. Typically there are 3 linear
axes in which the tool head and part move. Convention dictates that the main axis that drives the
part towards the work spindle is the Z axis, with a cross-traversing X axis and a vertically-
traversing Y axis. The work spindle is referred to as the C axis and, if a rotary table is incorporated,
its centre line is the B axis. Horizontal boring machines are often heavy-duty industrial machines
used for roughing out large components but there are high-precision models too. Modern machines
use advanced CNC control systems and techniques. Charles DeVlieg entered the Machine Tool Hall
of Fame for his work upon a highly precise model which he called a JIGMIL. The accuracy of this
machine convinced the USAF to accept John Parson's idea for numerically controlled machine tools.
MILLING MACHINE
A milling machine is a machine tool used to machine solid materials. Milling machines are often
classed in two basic forms, horizontal and vertical, which refers to the orientation of the main
spindle. Both types range in size from small, bench-mounted devices to room-sized machines.
Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the
material, milling machines also move the workpiece radially against the rotating milling cutter,
which cuts on its sides as well as its tip. Work piece and cutter movement are precisely controlled
to less than 0.001 in (unknown operator: u'strong' mm), usually by means of precision ground
slides and leadscrews or analogous technology. Milling machines may be manually operated,
mechanically automated, or digitally automated via computer numerical control.Milling machines
can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planing,
drilling) to complex (e.g., contouring, die sinking). Cutting fluid is often pumped to the cutting site
to cool and lubricate the cut and to wash away the resulting swarf.
19. Types and nomenclature
Mill orientation is the primary classification for milling machines. The two basic configurations are
vertical and horizontal. However, there are alternate classifications according to method of control,
size, purpose and power source.
Mill orientation
Vertical mill
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and
rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving
the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the
bed mill and the turret mill.
• A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to
the spindle axis to accomplish cutting. The most common example of this type is the Bridgeport,
described below. Turret mills often have a quill which allows the milling cutter to be raised and
lowered in amanner similar to a drill press. This type of machine provides two methods of cutting
in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee.
• In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the
spindle itself moves parallel to its own axis. Turret mills are generally considered by some to be
more versatile of the two designs. However, turret mills are only practical as long as the machine
remains relatively small. As machine size increases, moving the knee up and down requires
considerable effort and it also becomes difficult to reach the quill feed handle (if equipped).
Therefore, larger milling machines are usually of the bed type. Also of note is a lighter machine,
called a mill-drill. It is quite popular with hobbyists, due to its small size and lower price. A mill-drill
is similar to a small drill press but equipped with an X-Y table. These are frequently of lower quality
than other types of machines.
Horizontal mill
A horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal arbor
(see Arbor milling) across the table. Many horizontal mills also feature a built-in rotary table that
allows milling at various angles; this feature is called a universal table. While endmills and the other
types of tools available to a vertical mill may be used in a horizontal mill, their real advantage lies in
arbor-mounted cutters, called side and face mills, which have a cross section rather like a circular
saw, but are generally wider and smaller in diameter. Because the cutters have good support from
the arbor and have a larger cross-sectional area than an end mill, quite heavy cuts can be taken
enabling rapid material removal rates. These are used to mill grooves and slots. Plain mills are used
to shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex shape
of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any section desired.
These specialty cutters tend to be expensive. Simplex mills have one spindle, and duplex mills have
two. It is also easier to cut gears on a horizontal mill. Some horizontal milling machines are
equipped with a power-take-off provision on the table. This allows the table feed to be
synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid gears.
20. INDEXING HEAD
An indexing head, also known as a dividing head or spiral head, is a specialized tool that allows a
workpiece to be circularly indexed; that is, easily and precisely rotated to preset an gles or circular
divisions. Indexing heads are usually used on the tables of milling machines, but may be used on
many other machine tools including drill presses, grinders, and boring machines. Common jobs for
a dividing head include machining the flutes of a milling cutter, cutting the teeth of a gear, milling
curved slots, or drilling a bolt hole circle around the circumference of a part.
The tool is similar to a rotary table except
that it is designed to be tilted as well as
rotated. Most adjustable designs allow the
head to be tilted from 10° below horizontal
to 90° vertical, at which point the head is
parallel with the machine table. The
workpiece is held in the indexing head in
the same manner as a metalworking lathe.
This is most commonly a chuck but can
include a collet fitted directly into the
spindle on the indexing head, faceplate, or
between centers. If the part is long then it
may be supported with the help of an FIGURE 8: INDEXING PLATES
accompanying tailstock.
Manual indexing heads
Cross-section of an indexing head Interchangeable indexing plates Indexing is an operation of
dividing a periphery of a cylindrical workpiece into equal number of divisions by the help of index
crank and index plate. A manual indexing head includes a hand crank. Rotating the hand crank in
turn rotates the spindle and therefore the workpiece. The hand crank uses a worm gear drive to
provide precise control of the rotation of the work. The work may be rotated and then locked into
place before the cutter is applied, or it may be rotated during cutting depending on the type of
machining being done. Most dividing heads operate at a 40:1 ratio; that is 40 turns of the hand
crank generates 1 revolution of the spindle or workpiece. In other words, 1 turn of the hand crank
rotates the spindle by 9 degrees. Because the operator of the machine may want to rotate the part
to an arbitrary angle indexing plates are used to ensure the part is accurately positioned.
Direct indexing plate: Most dividing heads have an indexing plate permanently attached to the
spindle. This plate is located at the end of the spindle, very close to where the work would be
mounted. It is fixed to the spindle and rotates with it. This plate is usually equipped with a series of
holes that enables rapid indexing to common angles, such as 30, 45, or 90 degrees. A pin in the base
of the dividing head can be extended into the direct indexing plate to lock the head quickly into one
of these angles. The advantage of the direct indexing plate is that it is fast and simple and no
calculations are required to use it. The disadvantage is that it can only be used for a limited number
of angles. A dividing head mounted on the table of a small milling machine. The direct indexing
plate and center are visible facing the camera. An interchangeable indexing plate is visible on the
left side. Interchangeable indexing plates are used when the work must be rotated to an angle not
available on the direct indexing plate. Because the hand crank is fixed to the spindle at a known
21. ratio (commonly 40:1) then dividing plates mounted at the handwheel can be used to create finer
divisions for precise orientation at arbitrary angles. These dividing plates are provided in sets of
several plates. Each plate has rings of holes with different divisions. For example, an indexing plate
might have three rows of holes with 24, 30, and 36 holes in each row. A pin on the hand crank
engages these holes. Index plates with up to 400 holes are available. Only one such plate can be
mounted to the dividing head at a time. The plate is selected by the machinist based on exactly what
angle he wishes to index to.
Brown and Sharpe indexing heads include a set of 3 indexing plates. The plates are marked #1,
#2 and #3, or "A", "B" and "C". Each plate contains 6 rows of holes. Plate #1 or "A" has 15, 16, 17,
18, 19, and 20 holes. Plate #2 or "B" has 21, 23, 27, 29, 31, and 33 holes. Plate #3 or "C" has 37, 39,
41, 43, 47, and 49 holes.
Some manual indexing heads are equipped with a power drive provision. This allows the rotation of
the dividing head to be connected to the table feed of the milling machine instead of using a hand
crank. A set of change gears is provided to select the ratio between the table feed and rotation. This
setup allows the machining of spiral or helical features such as spiral gears, worms, or screw type
parts because the part is simultaneously rotated at the same timeit is moved in the horizontal
direction. This setup is called a "PTO dividing head".
NUMERICAL CONTROL
Numerical control (NC) refers to the
automation of machine tools that are operated
by abstractly programmed commands encoded
on a storage medium, as opposed to controlled
manually via handwheels or levers, or
mechanically automated via cams alone. The
first NC machines were built in the 1940s and
1950s, based on existing tools that were
modified with motors that moved the controls
to follow points fed into the system on
punched tape. These early servomechanisms
were rapidly augmented with analog and
digital computers, creating the modern
computer numerical control (CNC) machine FIGURE 9: A SIEMENS CNC MACHINE
tools that have revolutionized the machining
processes.
In modern CNC systems, end-to-end component design is highly automated using computer-aided
design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a
computer file that is interpreted to extract the commands needed to operate a particular machine
via a postprocessor (for specific controller), and then loaded into the CNC machines for production.
Since any particular component might require the use of a number of different tools-drills, saws,
etc., modern machines often combine multiple tools into a single "cell". In other cases, a number of
different machines are used with an external controller and human or robotic operators that move
the component from machine to machine.
22. TRANSMISSION SHOP
- U N D E R P O O R N A K O L A G A N I ( I I T K HA R A G P U R )
( 0 5 - 0 7 - 2 0 1 1 TO 1 1 - 0 7 - 2 0 1 1 )
Transmissions available:
1. Model No. HD-785-2 transmission (85 ton dumper)
2. Model No. BD-335X transmission (410 hp dozer)
3. Model No. CLVT-750 transmission (35 ton dumper)
4. Model No. Bh-85-1 transmission (Rear dumper)
Details covered:
1. Clutch combinations
2. Valve combinations
3. Pressure oils used
4. Fitting, engaging and disengaging of clutches
5. PTO housing
6. Testing parameters for HD-785
7. Fluid coupling and torque converter
BD355X BULL DOZER
SALIENT FEATURES
1. BEML BS6D170-1 diesel engine: Turbo
charged engine for superb fuel economy
and generous power to weight ratio for
powerful dozing.
2. Torqueflow transmission: Smooth and
responsive power shift with single-lever
control for instant speed and directional
changes.
3. Pilot operated hydraulic system: Offers FIGURE 10: OVERHAULING A HD-785 TRANSMISSION
effortless fine control of blade through
joy stick
4. Operator Comfort: Conveniently located arm chair steering control for enhanced operator
comfort.
5. Electronic Monitoring System: Intrdouction of state of the art electronic monitoring system,
fitted with cluster gauges.
6. Steering clutch & Brakes: Track-roller frames are made of high tensile steel for maximum
rigidity. The blade incorporates high-tensile steel at all key points to improve outstanding
resistance to wear
23. 7. Sturdy construction: High tensile steel blades of different configurations available for
varying types of working conditions and applications . The work attatchment is sturdy in
construction to withstand adverse ground conditions.
8. Sprockets: Bolt-on type segmented sprocket permits quick on site replacement. Special
grooved type floating seals and unique dust seals provide extended undercarriage life.
9. Reduced noise levels: Radiator, fuel tank, floor frame and the cabin are mounted on anti-
vibration rubber cushions to isolate vibration and to reduce noise levels.
Flywheel power (net): 310kW (416HP) @ 2000 r/min
Operating mass (with straight tilt dozer): 43850 kg
Torque converter:
In modern usage, a torque converter is
generally a type of hydrodynamic fluid coupling
that is used to transfer rotating power from a
prime mover, such as an internal combustion
engine or electric motor, to a rotating driven
load. The torque converter normally takes the
place of a mechanical clutch in a vehicle with an
automatic transmission, allowing the load to be
separated from the power source.
It is usually located between the engine's
flexplate and the transmission. The key
characteristic of a torque converter is its ability
to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a
reduction gear. Some of these devices are also
equipped with a temporary locking mechanism
which rigidly binds the engine to the
transmission when their speeds are nearly equal,
to avoid slippage and a resulting loss of FIGURE 11: TORQUE CONVERTER CUT-AWAY
efficiency. By far the most common form of
torque converter in automobile transmissions is the device described here. However, in the 1920s
there was also the pendulum-based Constantinesco torque converter. There are also mechanical
designs for continuously variable transmissions and these also have the ability to multiply torque,
e.g. the Variomatic with expanding pulleys and a belt drive.
Usage
• Automatic transmissions on automobiles, such as cars, buses, and on/off highway trucks.
• Forwarders and other heavy duty vehicles.
• Marine propulsion systems.
24. • Industrial power transmission such as conveyor drives, almost all modern forklifts, winches,
drilling rigs, construction equipment, and railway locomotives.
Function
Torque converter elements
A fluid coupling is a two element drive that is incapable of multiplying torque, while a torque
converter has at least one extra element—the stator—which alters the drive's characteristics during
periods of high slippage, producing an increase in output torque.
In a torque converter there are at least three rotating elements: the impeller, which is mechanically
driven by the prime mover; the turbine, which drives the load; and the stator, which is interposed
between the impeller and turbine so that it can alter oil flow returning from the turbine to the
impeller. The classic torque converter design dictates that the stator be prevented from rotating
under any condition, hence the term stator. In practice, however, the stator is mounted on an
overrunning clutch, which prevents the stator from counter-rotating with respect to the prime
mover but allows forward rotation.
Modifications to the basic three element design have been periodically incorporated, especially in
applications where higher than normal torque multiplication is required. Most commonly, these
have taken the form of multiple turbines and stators, each set being designed to produce differing
amounts of torque multiplication. For example, the Buick Dynaflow automatic transmission was a
non-shifting design and, under normal conditions, relied solely upon the converter to multiply
torque. The Dynaflow used a five element converter to produce the wide range of torque
multiplication needed to propel a heavy vehicle. Although not strictly a part of classic torque
converter design, many automotive converters include a lock-up clutch to improve cruising power
transmission efficiency and reduce heat. The application of the clutch locks the turbine to the
impeller, causing all power transmission to be mechanical, thus eliminating losses associated with
fluid drive.
Operational phases
A torque converter has three stages of operation:
• Stall. The prime mover is applying power to the impeller but the turbine cannot rotate. For
example, in an automobile, this stage of operation would occur when the driver has placed the
transmission in gear but is preventing the vehicle from moving by continuing to apply the brakes.
At stall, the torque converter can produce maximum torque multiplication if sufficient input power
is applied (the resulting multiplication is called the stall ratio). The stall phase actually lasts for a
brief period when the load (e.g., vehicle) initially starts to move, as there will be a very large
difference between pump and turbine speed.
• Acceleration. The load is accelerating but there still is a relatively large difference between
impeller and turbine speed. Under this condition, the converter will produce torque multiplication
that is less than what could be achieved under stall conditions. The amount of multiplication will
depend upon the actual difference between pump and turbine speed, as well as various other
design factors.
25. • Coupling. The turbine has reached approximately 90
percent of the speed of the impeller. Torque multiplication
has essentially ceased and the torque converter is behaving
in a manner similar to a simple fluid coupling. In modern
automotive applications, it is usually at this stage of
operation where the lock-up clutch is applied, a procedure
that tends to improve fuel efficiency. The key to the torque
converter's ability to multiply torque lies in the stator. In the
classic fluid coupling design, periods of high slippage cause FIGURE 12: A CUT-AWAY MODEL OF
the fluid flow returning from the turbine to the impellor to A TORQUE CONVERTER
oppose the direction of impeller rotation, leading to a
significant loss of efficiency and the generation of considerable waste heat. Under the same
condition in a torque converter, the returning fluid will be redirected by the stator so that it aids the
rotation of the impeller, instead of impeding it. The result is that much of the energy in the
returning fluid is recovered and added to the energy being applied to the impeller by the prime
mover. This action causes a substantial increase in the mass of fluid being directed to the turbine,
producing an increase in output torque. Since the returning fluid is initially travelling in a direction
opposite to impeller rotation, the stator will likewise attempt to counter-rotate as it forces the fluid
to change direction, an effect that is prevented by the one-way stator clutch.
Unlike the radially straight blades used in a plain fluid coupling, a torque converter's turbine and
stator use angled and curved blades. The blade shape of the stator is what alters the path of the
fluid, forcing it to coincide with the impeller rotation. The matching curve of the turbine blades
helps to correctly direct the returning fluid to the stator so the latter can do its job. The shape of the
blades is important as minor variations can result in significant changes to the converter's
performance. During the stall and acceleration phases, in which torque multiplication occurs, the
stator remains stationary due to the action of its one-way clutch. However, as the torque converter
approaches the coupling phase, the energy and volume of the fluid returning from the turbine will
gradually decrease, causing pressure on the stator to likewise decrease. Once in the coupling phase,
the returning fluid will reverse direction and now rotate in the direction of the impellor and
turbine, an effect which will attempt to forward-rotate the stator. At this point, the stator clutch will
release and the impeller, turbine and stator will all (more or less) turn as a unit.
Unavoidably, some of the fluid's kinetic energy will be lost due to friction and turbulence, causing
the converter to generate waste heat (dissipated in many applications by water cooling). This effect,
often referred to as pumping loss, will be most pronounced at or near stall conditions. In modern
designs, the blade geometry minimizes oil velocity at low impeller speeds, which allows the turbine
to be stalled for long periods with little danger of overheating.
26. ENGINE SHOP
- U N D E R M R . K R I S H N A M O HA N
(FROM 12.07.2011 TO 20.07.2011)
Engines available:
1) CUMMINS:
a) NT-495 (145hp-4 cylinder)
b) NT/A-495
c) NT-855
d) NT/A-855 (280 hp-6 cylinder)
e) NT-743
f) VT-1710
g) VT/A-1710
h) KT-1150
i) KT/A-1150
j) KT-2300 (900 hp-12 cylinder)
k) KT/A-2300
l) KT/A-38C
m) KT/A-3067 (1600hp-16 cylinders)
2) BEML:
a) 6D-170mm (410hp-6 cylinders)
b) 6D-140mm (280hp-6 cylinders) FIGURE 13: CRANKSHAFT GRINDING MACHINE
3) DDC (Detra Diesel Corp.)
a) S-2000 (1200hp-16 cylinders)
4) CATERPILLER:
a) DITA-3406 (400hp-6 cylinders)
b) DITA-3506 (870 hp-8 cylinders)
c) CAT-3508 (900 hp-8 cylinders)
Topics covered:
1. Cooling system
2. Air system
3. Lubrication system
4. Fuel system
5. Different manifolds
6. Turbocharger and supercharger in details
7. Construction of an air compressor
8. Construction of a water pump
9. Construction of a fuel injector
27. COOLING SYSTEMS
Cooling system consists of the following major parts:
Air/water
Pump
Cylinder block
Oil cooler
Cylinder head
Water manifold
Thermostat housing
AIR SYSTEMS
The air system consists of following important components:
Air cleaner
Turbocharger
After cooler
Intake manifold
Inlet valve
Combustion chamber
LUBRICATION SYSTEMS
The lubrication system consists of the
following important components:
Oil sump
Suction pipe
Oil pump
Oil regulator
Oil filter
Oil cooler
Main gallery
Sub gallery
Piston cooling nozzle gallery
Cylinder head
All moving components FIGURE 14: ENGINES KEPT AT CWS JAYANT WORKSHOP
Back to sump
28. FUEL SYSTEMS
The fuel system consists of the following important parts:
Fuel tank
Fuel filter
Fuel pump
o Pressure timing pump
o Fuel injection pump
Fuel manifold
Fuel injector nozzle
Combustion chamber
