SUMMER TRAINING PROJECT

REPORT

INDIA YAMAHA MOTOR PVT. LTD.

SUBMITTED BY:-

PRABHAT TIWARI

B.TECH

MECHANICAL DEPARTMENT

SESSION: 2012-2016

DIT, AMITY GROUP OF INSTITUTION

GREATER NOIDA, U.P

(AFFILIATED TO UTTAR PRADESH TECHNICAL UNIVERSITY)

PREFACE

As a part of course curriculum of Bachelor of Technology we were asked to undergo 4 to 6 weeks summer training in any organization so as to give us exposure to practical skill and competence to get us familiar with various activities taking place in the organization. Our institute also believe in close and continuous Industrial Academy interaction in order to enhance the capability of student to imbibe rich and practical exposure useful for the corporate world. I have put my sincere efforts to accomplish my objectives within the stipulated time. I have worked to my optimum potential to achieve desired goals. I came across some difficulties to make my objective a reality. With the kind help and genuine interest and the guidance of my supervisor, I tried my level best to conduct a research to gain a thorough knowledge about the project. I put the best of my efforts to bring out this piece of work; if anywhere, something is found unacceptable or unnecessary to the theme valuable suggestions are thankfully acknowledged Thanks and Regards Yours sincerely Prabhat Tiwari

ACKOWLEDGEMENT

I would like to express my gratitude to all the people who provided me with

support and guidance throughout the course of my summer internship

program

Firstly I would like to thank Mr. Bhavesh Kumar (HR department), Vijay Khanna

(HR department) and Shaima Tayyab (HR department) for giving me an

opportunity to undergo summer training at INDIA YAMAHA MOTORS PVT LTD,

Mathura road, Faridabad. I am deeply indebted to Mr. S.K Gulati and Mr.

Rajendra Kumar (Crankshaft department) without the supervision and

continued guidance of whom it wouldn’t have been possible to complete this

project.

I would also like to thank Mr. A.K Sharma for providing me this wonderful

opportunity to work with the YAMAHA family.

Thank you

Prabhat Tiwari

CONTENTS

1. Preface

2. Acknowledgement

3. Content

4. Overview

5. About Yamaha Motors

5.1. History

5.2. About India Yamaha Motors Pvt. Ltd

6. Manufacturing

6.1. Raw Material

6.2. The manufacturing process

6.3. Quality Control

7. Faridabad Plant

7.1. Gear

7.2. Camshaft

7.3. Body Cylinder

7.4. Head Cylinder

7.5. Axle

7.6. Connecting Rod

7.7. Crank

7.8. Crankcase Cover

8. Heat Treatment

OVERVIEW

INDIAN AUTOMOBILE INDUSTRY

Over a period of more than two decades the Indian Automobile industry has

been driving its own growth through phases. The entry of Suzuki Corporation in

Indian passenger car manufacturing is often pointed as the first sign of India

turning to a market economy. Since then the automobile sector witnessed

rapid growth year after year. By late 90’s the industry reached self-reliance in

engine and component manufacturing from the status of large scale importer.

With comparatively higher rate of economic growth rate index against that of

great global powers. India has become a hub of domestic and export business.

The automobile sector has been contributing its share has been contributing its

share to the shining economic performance of India in recent years.

With the Indian middle class earning higher per capita income, more

people are ready to own private vehicles including cars and two-

wheelers. Product movements and manned services have boosted in

the sales of medium and sized commercial vehicles for passenger and

goods transport. Side by side with fresh vehicle sales growth, the

automotive components sector has witnessed big growth. The domestic

auto components consumption has crossed rupees 9000 crores and an

export of one half size of this figure

As per Society of Indian Automobile Manufacturers (SIAM) the market share of

each segment of the industry is as follows:

ABOUT YAMAHA MOTORS

HISTORY

Yamaha's history goes back over a hundred years to 1887 when

Torakusu Yamaha founded the company, which began producing

reed organs. The Yamaha Corporation in Japan (then Nippon Gakki

Co., Ltd.) has grown to become the world's largest manufacturer of

a full line of musical instruments, and a leading producer of

audio/visual products, semiconductors and other computer related

products, sporting goods, home appliances and furniture, specialty

metals, machine tools, and industrial robots.

The Yamaha Motor Corporation, Ltd., begun on July 1, 1955, is a

major part of the entire Yamaha group, but is a separately

managed business entity from the Yamaha Corporation. The

Yamaha Motor Corporation is the second largest manufacturer of

motorcycles in the world. Yamaha Motor Corporation owns its

wholly-owned subsidiary in the U.S. called Yamaha Motor

Corporation, USA, that is handling not only motorcycles, but also

snow mobiles, golf carts, outboard engines, and water vehicles,

under the brand name of Yamaha as well.

In 1954 production of the first motorcycles began, a simple 125cc

single-cylinder two-stroke. It was a copy of the German DKW

design, which the British BSA Company had also copied in the

post-war era and manufactured as the Bantam.

About India Yamaha Motor Pvt. Ltd.

Yamaha made its initial foray into India in 1985. Subsequently,

it entered into a 50:50 joint-venture with the Escorts Group in

1996. However, in August 2001, Yamaha acquired its remaining

stake becoming a 100% subsidiary of Yamaha Motor Co., Ltd,

Japan (YMC). In 2008, Mitsui & Co., Ltd. entered into an

agreement with YMC to become a joint investor in the

motorcycle manufacturing company "India Yamaha Motor

Private Limited (IYM)".

IYM operates from its state-of-the-art-manufacturing units at

Surajpur in Uttar Pradesh and Faridabad in Haryana and

produces motorcycles both for domestic and export markets.

With a strong workforce of more than 2,000 employees, IYM is

highly customer-driven and has a countrywide network of over

400 dealers.

MANUFACTURING

India Yamaha Motor’s manufacturing facilities comprises of 2 state-of-the-art

Plants at Faridabad (Haryana) and Surajpur (Uttar Pradesh). The infrastructure

at both the plants support of motorcycles and its parts for the domestic as well

as overseas market. It has In-house facility for Machining, Casting, Welding

process as well as finishing processes of Electroplating and Painting till the

assembly line.

The stringent Quality Assurance norms ensure that its motorcycles meet the

reputed International standard of excellence in every sphere.

RAW MATERIAL:-

The primary raw materials used in the manufacture of the body of motorcycle

are metal, plastic and rubber. The motorcycle frame is composed almost

completely of metal. The frame may be overlaid with plastic. The tires are

composed of rubber. The seat is made from a synthetic substance, such as

polyurethane.

The cylinder piston, made of aluminium alloy is an essential component of

engine. It is fitted with piston rings made of cast iron. The crankshaft and

crankcase are made of aluminium. The engine also contains a cylinder barrel,

typically made of cast iron or light alloy.

THE MANUFACTURING PROCESS:-

1. Raw materials as well as parts and components arrive at the

manufacturing plant by truck. As part of just-in-time delivery system on

which many plants are scheduled, the materials and parts are delivered at

the place where they are used or installed.

2. Manufacturing begins in the weld department with computer-controlled

fabrication of the frame from high strength frame materials. Components

are formed out of tubular metal and/or hollow metal shells fashioned from

sheet metal shells fashioned from sheet metal. The various sections are

welded together. This process involves manual, automatic and robotic

equipment.

3. In the plastic department, small plastic resin pellets are melted and

injected into molds under high pressure to form various plastic body trim

parts. This process is known as injection molding.

4. Plastic and metal parts and components are painted in booths in the paint

department using a process known as powder-coating. A powder coating

apparatus works like a large spray-painter, dispersing paint through a

pressurized system evenly across the metal frame.

5. Painted parts are sent via overhead conveyors or tow motor to assemble

department where they are installed on the frame of the motorcycle.

6. The engine is mounted in the painted frame, and various other

components are fitted as the motorcycle is sent down the assembly line.

7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags,

light, radios and hundreds of other parts are installed on the motorcycle

frame.

QUALITY CONTROL:-

At the end of the manufacturing line and assembly line, quality control

inspectors undertake a visual inspection of the motorcycle and its part’s

finishing, painted finish and fit of parts. The quality control inspectors also feel

the motorcycles with gloved hands to detect any bumps or defects in the finish.

Each motorcycle is tested on a dynamometer.

Inspectors accelerate the motorcycle from 0-60mph. During the acceleration,

the “dyno” tests for acceleration and braking, shifting, wheel alignment,

headlight and taillight alignment and function, horn function and exhaust

emissions. The finished product must meet international standards for

performance and safety. After the dyno test, a final inspection is made of the

completed motorcycle.

FARIDABAD PLANT

The manufacturing unit of Faridabad plant constitutes Casting, Machining,

Welding, Heat treatment and Painting of parts of two wheelers of IYM.

Following are the parts of two wheelers manufactures in Faridabad Plant of

IYM:-

1. Gear

2. Axle Main

3. Cylinder Head

4. Cylinder body

5. Crank

6. Crankcase

7. Cover crankcase

8. Cam and Cam shaft

9. Connecting rod

GEAR

GEAR BLANK from the vendor is brought to the Faridabad plant for

manufacturing of gears. Then it is passed through the following processes:-

Turning, facing, boring and chamfering

Hobbing

Broaching

Marking

Washing

Shaving

Heat treatment

Hobbing

Hobbing is a machining process for making gears, splines, and spockets on a

hobbing machine, which is a special type of milling machine. The teeth or

splines are progressively cut into the gear blank by a series of cuts made by a

cutting tool called hob. Compared to other gear forming processes it is

relatively inexpensive but still quite accurate, thus it is used for broad range of

parts and quantities.

It is most widely used gear cutting process for creating spur and helical gear

and more gears are cut by hobbing than any other process since it is relatively

quick and inexpensive.

USES

Hobbing is used to make following types of finished goods:

Cycloid gear

Helical gears

Involute gear

Ratchets

Splines

Sprockets

Spur gears

Worm gears

Hobbing is used to produce most throated worm wheels but certain tooth

profiles cannot be hobbed. If any portion of hob profile is perpendicular to axis

then it will have no cutting clearance generated by usual backing off process

and it will not cut well.

BROACHING

For very large gears or splines a vertical broach is used. It consists of a vertical

rail that carries a single tooth cutter formed to create the tooth shape. A rotary

table and a Y axis are the customary axes available. Some machines will cut to a

depth on the Y axis and index the rotary table automatically. The largest gear

are produced on these machines.

Other operation such as broaching work particularly well for cutting teeth on

the inside. The downside to this is that it is expensive and different broaches

are required to make different sized gears. Therefore it is mostly used in very

high production runs.

MARKING

Marking is done on the Primary Gear and Gear Balance Weight. In this process

in mark is made on a certain distance from the centre of the gear on both types

of gear so that at time of assembly all the gear should be properly mounted

such as no misalignment is present in gear assembly, otherwise the

transmission system of vehicle fails during the operation.

CAMSHAFT

Camshafts can be made out of several different types of material. These

include Chilled iron casting and Billet steel.

Chilled Iron Casting: this is a good choice for volume production. A chilled iron

camshaft has a resistance against wear because the camshaft lobes have been

chilled, generally making them harder.

Billet Steel: when a high quality camshaft is required, engine builder and

camshaft manufacturers choose to make the camshaft from steel billet. One

example being EN40b. When manufacturing a camshaft from EN40b, the

camshaft will also be heat treated via gas nitriding, which changes the micro-

structure of the material. It gives a surface hardness of 55-60 HRC. These types

of camshafts can be used in high-performance engines.

Processes

Various process involve in the manufacturing of cam shaft according to

operating machines are:-

Facing

Turning operation

Keyway drilling and tapping operation

Oil hole drilling operation

Cam grinding operation

Grinding operation

Lapping operation

Washing operation

BODY CYLINDER

Body of cylinder of engine in made of aluminium in Casting shop of Faridabad

plant. In casting liquid aluminium is poured into the mold, which contains the

hollow cavity of desired shape, and then allowed to solidify. The solidify part is

known as casting which is ejected or broken out of the mold to complete the

process.

Initially it has poor surface finish and defects, so it is brought to the Machining

shop for giving desired accurate dimension and surface finish.

Machine/Operator-wise operation done on the Body cylinder are:-

Camera Vision testing

Face milling, drilling and boring A face

Milling, dowell and drilling B face

Milling, drilling and tapping C face

Dowell and rough boring B face

Fine boring

Internal diameter honing

Internal diameter testing

Air plug gauge setting

Oil extracting machining

Date code marking

Washing and air cleaning

Leak testing

HEAD CYLINDER

Like Body cylinder it is also made up of Aluminium in casting shop and

according to its desired shape then it is also brought to the Machine shop for

removal of defects, giving more accurate dimension and surface finish.

Machine-wise process involve in the manufacturing of Head cylinder are:-

Spot facing and drilling

Milling and drilling

Right fixture Exhaust facing, rough guide hole drilling & Left side inlet

facing/guide hole drilling

Right side exhaust, left side inlet facing and threading

Right side exhaust, left side exhaust boring and threading

Right side facing, left side inlet facing, drilling and tapping

Right side exhaust, left side inlet rocker milling

Right side exhaust, left side inlet parent boring

Parent bore inspection

Right side spark hole facing, threading, left side hole drilling and reaming

Rough cambore, face milling, drilling and threading

Mid-washing

Air blow procedure

Air plug gauge inspection

Seat and guide press

Exhaust valve seat machining

Inlet valve seat machining

Cambore fine boring, drilling and reaming

Deburring

Final washing

Air blow procedure

Leak inspection

AXLE MAIN

The method includes heating a billet at a heating station to a predetermined

temperature, forging the heated billet at a forging station to form a machined

axle. This axle is brought to the Faridabad plant from vendor and processed in

machining shop for desired accurate shape, dimension and surface finish.

The process involves are:-

Turning

Deburring

Drilling

Oil hole drilling

Washing

Hobbing

Threading

CONNECTING ROD

A standard shape of connecting rod with poor surface finish is brought from

vendor to the Faridabad plant where whereas operation is done on it in

Machining and heat treatment shop to give it proper accurate dimension, good

surface finish and hardness.

Operation carried out in Machining shop are:-

Small end drilling

Small end internal diameter drilling

Small end champering

Big end boring and champering

Small end oil hole drilling

Heat treatment: In heat treatment shop for carburizing it is kept for 9 hours at 930 degree

celsius and then for diffusion it is kept for 4 hours

Then again it is brought to the machine shop for:

Both end face grinding

Honing

Washing

CRANK

Like some other parts forged crank is also bought from vendor of standard

shape and poor surface finish. In machining shop it various operations are

done on it to give it a defect less and accurate dimension and also good

surface finish. The machine-wise operations done over it are:-

Centering and facing

Pin turning

Pin hole boring

Thread rolling

Keyway milling

Induction hardening

Outer diameter grinding

Thrust facing

Internal diameter grinding

COVER CRANKCASE

Like engine cylinder it is also manufactured in casting shop of Faridabad plant

by melting the metal and poring it into the mold and then extracting the

solidify casting from the the mold. From casting shop this cover crankcase is

brought to the machine shop for the following process to give it a good surface

finish and preparing its desired dimensions:-

Milling, dowell and boring

Drilling, tapping, boring of screw hole

Drilling and chamfering

Washing

Air-blow

Visual inspection

HEAT TREATMENT

Heat treating is a group of industrial and metal working processes used to alter

the physical and sometimes chemical properties of a material. The most

common application is metallurgical. Heat treatments are also used in the

manufacture of many other materials such as glass, Heat treatment involves

the use of heating or chilling normally to extreme temperatures to achieve a

desired result such as hardening or softening of material. Heat treatment

techniques include annealing, case hardening, precipitation strengthening,

tempering and quenching. It is noteworthy that while the term heat treatment

applies only to processes where heating and cooling are done for specific

purpose of altering properties intentionally, heating and cooling often occur

incidentally during other manufacturing processes such as hot forming or

welding.

TECHNIQUES:

The heat treatment techniques used for manufacturing of parts of two wheeler

in Faridabad plant are:-

Annealing

It consists of heating a metal to a specific temperature and then cooling at a

rate that will produce a refined microstructure. It is often used to soften a

metal for cold working to improve machinability or to enhance properties like

electrical conductivity

Normalizing

Normalizing is a technique used to provide uniformity in grain size and

composition throughout an alloy. The term is often used for ferrous alloys that

have been heated above the upper critical temperature and then cooled in

open air.

Stress relieving

Stress relieving is a technique to remove or reduce the internal stresses created

in a metal. These stresses may be caused in a number of mays, ranging from

cold working to non-uniform cooling. Stress relieving is usually accomplished by

heating a metal below the lower critical temperature and then cooling

uniformly.

Aging

Some metal are classified as precipitation hardening metals. When a

precipitation hardening alloy is quenched, its alloying elements will be trapped

in solution, resulting in a soft metal. A “solutionized” metal will allow the

alloying element to diffuse through the microstructure and form intermetallic

particles. These intermetallic particles will nucleate and fall out solution and act

as a reinforcing phase, thereby increasing the strength of the alloy. Alloys may

age “naturally” meaning that the precipitates form at room temperature, or

they may age “artificially” when precipitates only form at elevated

temperatures. In some applications, naturally aging alloy may be stored in a

freezer to prevent hardening until after further operation-assembly of rivets,

for example, may be easier with a softer part.

Quenching

Quenching is a process of cooling a metal very quickly. This is most often done

to produce a martensite transformation. In ferrous alloys, this will often

produce a harder metal, while non-ferrous alloys will usually become softer

than normal.