![It is really a matter of great pleasure to acknowledge the invaluable guidance,
enormous assistance and excellent co-operation extended to me by TATA MOTORS
Jamshedpur in the completion of my project.
To start with, I would like to express my gratitude towards all the people who have
contributed their precious time and effort to help me in the project. I would like to
thank Mr. Ashok Kumar [ AGM ( Maintenance ), Jamshedpur Works, Frame Factory
] and Mr. Rakesh Cheeli [ Manager ( Maintenance), Jamshedpur Works, Frame
Factory ]; for their guidance, support, motivation and encouragement throughout
the project period.
Their readiness for consultation at all times, their valuable remarks, their concern
and assistance have been invaluable. I would also like to express my heartfelt
thanks to my friends and my project partner. Last but not the least; I would also
extend my sincere gratitude to Department of Mechanical Frame Factory, Tata
Motors Jamshedpur for availing the facilities required for my project analysis.
I also express my heartiest gratitude to all the people of Tata Motors for their
constant help and support. This work would not have been possible without the
support and help from them.](https://image.slidesharecdn.com/projectsayansarkar-150115132539-conversion-gate01/85/frame-manufacture-overview-2-320.jpg)
frame manufacture overview
- 1. Manufacture of Frame with the study of Assembly Line & 5000 Ton Press SUBMITTED BY SAYAN SARKAR DEPARTMENT OF MECHANICAL ENGINEERING INDIAN INSTITUTE OF ENGINEERING SCIENCE & TECHNOLOGY,SHIBPUR
- 2. It is really a matter of great pleasure to acknowledge the invaluable guidance, enormous assistance and excellent co-operation extended to me by TATA MOTORS Jamshedpur in the completion of my project. To start with, I would like to express my gratitude towards all the people who have contributed their precious time and effort to help me in the project. I would like to thank Mr. Ashok Kumar [ AGM ( Maintenance ), Jamshedpur Works, Frame Factory ] and Mr. Rakesh Cheeli [ Manager ( Maintenance), Jamshedpur Works, Frame Factory ]; for their guidance, support, motivation and encouragement throughout the project period. Their readiness for consultation at all times, their valuable remarks, their concern and assistance have been invaluable. I would also like to express my heartfelt thanks to my friends and my project partner. Last but not the least; I would also extend my sincere gratitude to Department of Mechanical Frame Factory, Tata Motors Jamshedpur for availing the facilities required for my project analysis. I also express my heartiest gratitude to all the people of Tata Motors for their constant help and support. This work would not have been possible without the support and help from them.
- 3. This is a project through which we have aimed to achieve an understanding and learning of development of a product straight from its conception to manufacturing, encompassing all the stages such as Initial Calculations, Designing, Material Selection and Manufacturing considerations.
- 4. To study of Decoiler and Straightner used for long member. To study materials generally used for manufacturing long member used in frame. To study the processes taking place on Assembly Line. To study the working of 5000 Ton Press ( Hydraulics ). To study PTCED used in Frame Shop. To study the processes taking place on Frame Line I, II and III.
- 5. Type of Steel Used Dimension ( in mm ) Application E 46 Steel 7 X 388 Heavy Commercial Vehicle 7 X 321 Light Commercial Vehicle 7 X 362 Reinforcement 5 X 318 Light Commercial Vehicle • E 46 Steel Sheet required for the manufacture of Long Member is taken in Coiled Form which is decoiled using Decoiler. • Range of Long Member usually lies between 4m to 12m.
- 8. A frame is the main structure of the chassis of a motor vehicle
- 9. 5000T Press Long Member Packing and Despatch Main Road Pre Treatment Cathode Electrode Depostion Frame Assembly Line 1 Frame Assembly Line 2 Paint booth and Baking oven Walk Way Assembly Line 1 Walk Way Assembly Line 2 Walk Way Final Rectification
- 10. • Decoiler is a mechanical component in which the sheet metal, available in coiled form which is used for manufacturing of long member, is de-coiled. • Hydraulic Motor is present for tightening • The pressure arm is located on the to maintain the contact of the coil. • Some of the initial cut pieces are dumped because of their hardness and not straight cut. • A red indicator is there to signal the presence of the coil.
- 11. The machine is suitable for synchronizing with wire feeder or strip feeder. Synchronization will enable the machine to start unwinding the machine when there is consumption of material in the process. Otherwise the unwinding activity is stopped. It is a heavy construction by design to sustain the load of the material in the form of coil. The construction consist of three wings with adjustable jaws(either mechanized or manual). The unwinding action takes while the motor and gear box cranks the wings. Center of gravity is taken care in the design. The rotation is controlled by a limit switch or a wire with no potential supply to enable or disable the unwinding action with reference to the consumption of the material. The equipment and the covers are fully protected from getting corroded by means of zinc blue /black/green and powder coating.
- 12. Decoiler is used in press shops and other engineering applications where in the sheets are wires in the form of coil is being unwound in a mechanized way to feed the same to the next stage. • Complete electrical controls. • Motor, Couplings and Gear box assembly. • Lubrication Provision. • Protection guards. • Manual and motorized adjustment of jaws. • Limit switch control for synchronizing with feeder or Press. • Service and maintenance schedule chart.
- 14. The machine is suitable for synchronizing with strip feeder, power press and pneumatic presses. It is a heavy construction by design to sustain the stress levels while it remove the bends in the sheets. The construction consist of the Ground hardened and hard chrome coated bottom set and top set of rollers. The bottom rollers are mutually linked by gears driven by a main drive motor through gear box. There are totally one set of feed rollers which is used for feeding the sheets. Top rollers are individually adjustable to adjust and improve the straightness. The rollers are adjustable as a set of gang. The machine is suitable for synchronizing with strip feeder, power press and pneumatic presses. It is a heavy construction by design to sustain the stress levels while it remove the bends in the sheets. The construction consist of the Ground hardened and hard chrome coated bottom set and top set of rollers. The bottom rollers are mutually linked by gears driven by a main drive motor through gear box. There are totally one set of feed rollers which is used for feeding the sheets. Top rollers are individually adjustable to adjust and improve the straightness. The rollers are adjustable as a set of gang. The equipment and the covers are fully protected from getting corroded by means of zinc blue /black/green and powder coating.
- 15. Decambering is the metalworking process of removing camber, or horizontal bend, from strip shaped materials. The material may be finite length sections or continuous coils. Decambering resembles flattening or levelling processes, but deforms the material edge (left or right) instead of the face (up or down) of the strip.
- 17. Basic check valve allows fluid to flow in one direction, in this case from bottom to top. Shown are ISO symbol and cross-sectional photo of spring-loaded check valve. The spring keeps fluid from flowing unless downstream pressure acting on the poppet overcomes spring force. • Refers to the shifting of valves from fully open to fully closed. • It causes the flow to rapidly accelerate and decelerate. • Three types of Valve Positions : a ) Extend b ) Retract c ) Neutral • Proportional valves on the other hand control direction and speed, can also control actuator direction, speed, acceleration and deceleration. TypesofDirectionalControl Valve Discrete ( More than two or three positons ) Proportional Digital ( On and Off Positons )
- 18. • Primary Characteristics for selecting a Directional Control Valves are : a ) Number of Fluid Ports. b ) Number of Directional States of Positions the valve can achieve. • Number of Position refers to the number of distinct flow paths a valve can provide ( 4-Port,3-Position Spool Valve ).
- 19. Schematic shows simple circuit to control cylinder extension and retraction using a 4-port, 3-position spool valve. Arranging digital valves into a hydraulic integrated circuit allows them to accomplish the same functions as discrete spool-type valves while retaining the advantages of digital valves.
- 20. • Main Cylinder • Ram Locking Cylinder • Ejector • Die Caterpillar • Cushion • Prefill • Tool Carriage • Ram Slide • Damping Cylinder • Straightner Cassette • Tool Clamping Cylinder • Slide Lubrication Tank • Hydro Motor • IFS Conveyor Belt • Magnetic Transverse • OFS • Shearing Blade • RAM • Cassette • Measuring Head • Kohler Pump • Centering Cylinder • Tool Turnover Device
- 22. There are 21 Ejectors connected in the 5000 Ton Press, The primary objective of the ejector is to eject the long member when the head ram is moving upwards after notching, forming and piercing process.
- 24. • A device for shifting the control members of hydraulic actuating mechanism with simultaneous power amplification of the controlling action. • A cylinder or fluid motor that converts hydraulic power into useful mechanical work. • Actuators are used to pivot a joint. Actuators Rotatory Actuators Helical Spline Enclosed Piston Crank Scotch Yoke Rack and Pinion Piston Chain Bladder and Vane Actuator Single Vane Double Vane
- 25. 1 • PREWASH SYSTEM 2 • SHOT BLASTING 3 • DIP DEGRESSING 4 • WATER RINSE 5 • DEIONISED RINSE - I 6 • DEIONISED RINSE - 2
- 26. 9 • CED 10 • ULTRA FILTRATION-1 11 • ULTRAFILTRATION- 2 12 • RECYCLED DEMINERALISED WATER 13 • BAKING OVEN 14 • LINE 7 • TECTALIS ( 5800 ) 8 • DEIONISED RINSE-3
- 27. Fitment of Front SPG. Hanger BKT. And Reinforcement Fitment of ENG MTG. and 10 Dia. Riveting Slide Support Riveting and Gusset Fitment SPG. HANG BKT. BOLT ( M14 ) Tightening Hole Alignment and 10 Dia Bolt Tightening Fitment of Cross Members 10 Dia. Horizontal Riveting END CM Bolt Tightening Rear SPG. BKT. Bolt Tightening OPERATINGSTATIONSOF FRAME SHOPLINE 1 & 2
- 28. Hole Alignment and Rivet Insertions, END CM Bolt Tightening 10 and 12 Dia Horizontal Riveting Vertical ( 10 and 12 Dia ) Riveting Frame Inversion 12 Dia Horizontal Riveting and END CM BOLT Tightening BOLT Tightening 10 and 12 Dia Riveting, Inspection Final Inspection and Dispatch to Paint Shop Rectification Frame Painting Frame Baking Oven - 1
- 29. Riveting Operation Nut Runners Frame and Operations Performed on it
- 30. Frame Drop Chasis Number Punching Link Rod Fitment Propeller Shaft Fitment Lift Axle Kit Fitment Front Leaf Spring Fitment Rear Leaf Spring Fitment Steering Gear Box Fitment OPERATINGSTATIONSOF ASSEMBLY LINE
- 31. Rear Axle/Lift Axle Drop Front Axle/Dummy Axle Drop Rear/Dummy Axle Tightening Front/Lift Axle Tightening Quality Gate Chasis Inversion Brake/Fuel Pipe Fitment Front Shock Absorber and Steering Pipe Fitment Engine Drop Propeller Shaft Fitment with Gear Box
- 32. Mounting Processin ASSEMBLY LINE
- 33. Silencer Muffler Fitment/Quality Gate Radiation Drop Fuel Tank BKT. Fitment Cab/Cowl Drop Battery BKT. Fitment Battery Drop and Fuel Tank Fitment Wheel Fitment Wheel Nut Tightening Clutch Oil/Coolant/Diesel Filling Steering Oil Feeling/Engine Cranking
- 34. Spare Wheel Fitment/Air Leakage Test QA Check Quality Gate Side Shield Fitment Smoke Test
- 35. Side Layout of Assembled Truck ( Ready for Testing) Front Layout of Assembled Truck ( Ready for Testing)
- 36. THANKYOU