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APRACTICAL SUMMER TRAINING

IN

Submitted in partial fulfillment for the award of

Degree of Bachelor of Technology in

Mechanical Engineering

2015-16 Presented By:- SHUBHAM JAIN 4th Year ME12EGJME106

Submitted To:-Mr. Madhavendra SexenaMr. Gautam GunjanME Dept.

HISTORY INTRODUCTION OF LEYLAND PRODUCTS Axle assembly Chassis assembly Project Conclusion

CONTENTS

Ashok Leyland is an Indian automobile manufacturing company based in Chennai, India. Founded in 1948, it is the 2nd largest commercial vehicle manufacturer in India, 4th largest manufacturer of buses in the world and 16th largest manufacturer of trucks globally. Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment with a market share of 28% (2007–08). With passenger transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment. The company claims to carry more than 60 million passengers a day, more people than the entire Indian rail network. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. However Ashok Leyland has presence in the entire truck range starting from 7.5 tons to 49 tons. With a joint venture with Nissan Motors of Japan the company made its presence in the Light Commercial Vehicle (LCV) segment (<7.5 tons).

HISTORY

Applications: • CityEngine: "H" Series - 6 CYL. Diesel CRS BS3Maximum Power: 225 hp (165 kw) @ 2500 rpmMaximum Torque: 800Nm @ 1400-1900 rpmSteering: Brakes: Full air, dual line, S-cam

JANBUS BS3 (Bus)

U- 1619 BS4 (TRUCK)Applications: Stone quarry, Marble , Granite ,Sand, Bricks, Road Construction

Engine: Neptune BS4 Turbocharged Intercooled

Power: 190 HP@ 2300 rpm

Torque: 700 Nm @ 1100-1900 rpm

PARTNET (Light Vehicle)PARTNER - the big brother of DOST is a next generation LCV truck with 4 ton payload capacity. Partner with its superior advanced ZD30 engine, excellent mileage and comfortable cabin design is on its way to enthrall.

Defence Vehicles

FRONT AXLE ASSEMBLY :

Front Axle is one of the main component of an auto mobile, it gives direction to the vehicle.

Axle Beam Print the details (date, S. no.) Axle arm Bearing (thrust) Sims (20,40,10) King pin (mark should be upper) Quarter pin (big torque 45nm, small) Bottom cover (torque 15nm) Mesh nut, Dummy bolt (max. Cut screw) Truck rod/ Tie rod Upper cover + gas kit (brown colour, three bolts & middle

Greece nipple) Toe-in setting (0.5) Break shoe Greece filling in the Greece nipple Greece seal

FRONT AXLE COMPONENTS

Big bearing Distance peace Hub Small bearing Break drum (450gm Greece is used) I-joint

DESCRIPTION :

I-Beam : I-Beam is used in axle to take the stress, I- beam has maximum strength.

Axle Arm : axle arm bears the brake assembly and drum.

1 Right Side axle arm 2 Left Side axle arm

Track Rod : Track rod joins the two axle arms thus both the wheels to enhance the motion in same direction while turning.

Track Rod Lever : Track rod lever connects the track rod with axle arm on both sides.

Steering Lever : Steering Lever is used to give the direction.

Brake Assembly and Brake Drum : Brake assembly consists of slack adjuster and brake chamber. These are operated by compressed air which expands the assembly and brake drum constraints the motion.

Hub : Hub is an essential component of assembly which connects other components and provides motion.

Bearing : Bearings provide relative motion between two components.

Break shoe (torque 80nm)Remove the shaftCollar big (internal)Tapered roller bearingSimsDistance peaceHubSmall bearingCheck dry & wetCollar small outerChuck nutLock nutBreak nut

MAJOR COMPONENT OF REAR AXLE

Gas kitShaftU-joint

Axle Casing : Axle casing is the main part of rear axle and it has maximum strength. It has a differential box.

Axle Shaft : Axle shaft is also known as drive shaft and it is used to provide the motion from differential box to wheel.

Hub : Hub is used to transfer the motion from axle shaft to wheel.

Brake Assembly : brake assembly is consists of slack adjuster and booster or brake chamber. These are operated by compressed air.

Booster :

Brake Drum :

CHASSIS ASSEMBLY IN SHOP-2-In shop -2 chassis assembly takes place in 10 stages

on an assembly line. time of each stage is around 24 minutes. A chassis card is signed by the workers at each stage after doing the work for self – certification. After chassis assembly the chassis becomes off – track and goes for road testing.

CHASSIS ASSEMBLY

Axle dressingChassis couplingTorque stagesBracketing stageAir pipingEngine mounting stage -1Engine mounting stage -2Lubrication & tire mounting stageOff track -1Off track -2

DIFFERENT STAGES OF ASSEMBLY LINE

FrameFront springFront axleRear springRear axleAxle shaftShock absorberSteering gearEngineClutchGear boxFuel injection pumpAlternator

COMPONENTS USED FOR ASSEMBLY

StarterMotorAir compressorPropeller shaftRadiatorBatteriesFront end structureTail cableFuel tank

Project ( Assemble a old BS -3 Truck)

WiringHoses (intake, outlet)Check the torqueAir pipingSilencer mountingPropeller shaftBracketsEngine and gear box mountingRadiatorCooling fanAir filterCrownSteering wheel

I have learnt whole assembly of front & rear axle.

I have learnt assembly of chassis.

CONCLUSION