Arpit project

Departmentof Mechanical engineering
Sunrise faculty of engineering, Udaipur Page 1
PROJECT REPORT
EICHER ENGINES, ALWAR
(A Unit of TAFE Motors & Tractors Limited)
A Wholly Owned Subsidiary of TAFE
(A Unit of TAFE Motors & Tractors)

PROJECT REPORT
(INDUSTRIAL TRAINING MAY-JULY2016)
Dissertation Report Submitted on
Metallurgical testing Of Valtra Engine Component
RAJASTHAN TECHNICAL UNIVERSITY, KOTA
Towards The Partial Fulfillment for the Course Of
Bachelor of Engineering
By
Arpit Jain
Roll no.-13EIUME007
B.tech mechanical engineering2013-17
SUBMITTED TO-: GUIDE BY-:
Mr. Rahul Kumar Mr. Shelender Sharma
Jr. Manager-QSA Manager
EICHER ENGINES, ALWAR EICHER ENGINES, ALWAR

INDEX
S.No. Topic Page no.
1 Declaration 3
2 Acknowledgement 4
3 Introduction aboutcompany 5
4 Productrange 8
5 Eicher engine product 9
6 Process flow chart 13
7 An over look into the system of Eicher Engines 15
8 Project- Inspection of The Composition of
Material Valtra Engine Component
23
9 Conclusion 58
10 References 59

DECLARATION
I hereby declare that the project work entitled “Inspection of The Composition
of Material Of Valtra Engine Component” is an authentic record of my own
work carried out at EICHER ENGINES (TMTL), Alwar as requirement of two
month (sixty days) project semester for the award of degree of B.tech
Mechanical Engineering, Rajasthan technical university, kota, under the
guidance of Mr. Rahul kumar during may to july2016. The empirical findings in
this report are based on the data educated myself. This is my original work and
cannot be submitted partially or wholly to any other university or institute for
award of this or any other degree or diploma.
Arpit Jain
Date: - ……………… roll no.:- 13eiume007
Certified that the above statement made by the student is correct to the best
of our knowledge and belief.
………………
Vibhu Joshi
Asst. manager,
Human resource,
TMTL, Alwar,

Acknowledgement
Before I startwith the details of my project, I would like to add a few heartfelt words for
the people who were the partof my projectin numerous ways, thepeople who gave me
the immense supportrightfromthe stage from the stage where I was noviceto the
engines industry.
Firstof all I would like to express my deep senseof gratitude to Mr. Sudhir Jain, who gave
me opportunity to undertaketraining in this organization. I have appreciation and regards
for their constantencouragement, constructivecriticism and sympathetic understanding
throughoutthe courseof this training.
I would like to thank my mentor Mr. Rahul kumar (Jr. Manager-QSA)for those
opportunities he gaveme to sharehis ideas and knowledge in a large variety of settings
and senseof quality that I learnt from him are truly uncommon. I am very thankful to him
for his wiseand synergetic help throughoutmy training period.
I would like to thank whole metallurgy department and RQC department team for
always helped me in increasing my knowledgeand understanding of working in an
organization.
I express my gratitude to all the other employees of Eicher Engines for making my
training at the company wonderfulexperience.
Arpit

INTRODUCTION ABOUT COMPANY
 Established in 1961
 Chennai based amalgamation group
 Turnover RS. 37000 Crores
 C.E.O. Mrs. Malika Srinivaasan
 In December 2003, TAFE acquired Eicher’s Tractor plant at Mandideep, Engines Plant at Alwar and
Transmission plant at Parwanoo through the formation of a wholly owned subsidiary, TAFE Motors
and tractors Limited (TMTL)
TAFE PROFILE
Tractors and farm equipment limited (TAFE) is a unit company of the amalgamation group , one
of India’s largest light engineering group with diverse in diesel engines, automobile components,
tractors and related farm machinery, lubricants, panel instrument, hydraulic pumps, engineering
tools, storage batteries, paints, engineering plastics, automobile franchises and printing apart
from interests in agribusiness , book selling and publishing.
TAFE was established in 1961 to manufacture and market a range of Massey Ferguson tractors
and related farm equipment in India. One of the largest tractors manufactures in India, TAFE has
collaboration with AGCO Corporation, headquartered in Duluth, Georgia, which is one of the
largest manufactures, designers and distributors of agricultural equipment in the world.
TAFE was the first company to market a total package of tractors and farm equipment to not
only provides farm power but also interfaces to transform the farm power to increased farm
productivity. TAFE was also the first to introduce the direct injection technology in India. Thereby
initiating considerable fuel saving and the result economies in tractors operation cost to its
customers.
TAFE was also first Indian manufacturer to launch a 75 HP tractor to cater to the emerging need
of very large farms and agri- businesses. Whit three manufacturing locations at Chennai
(Sembiam), Madurai (kalladipatti) and Bangalore (Doddaballapur), TAFE has a large
manufacturing base. Its Madurai plant, the latest and possibly the largest such plant in the
country is specially tailored to take on short run production batches to the exacting standards
demanded by advanced countries. All its plant and sales offices are linked by VSAT providing fast
and efficient communications and data linkage another first of its kind in India.

TAFE is also involved in the following areas, apart from its core business of manufacturing
and marketing tractors.
1. TAFE has developed a range of matching trailers, implements and accessories. These
are marketed through TAFE’s dealer network by a totally owned subsidiary.
2. TAFE, through TAL is also involved in the marketing and distribution of lubricants and
greases for tractors through its dealer network.
3. TAFE is also involved in the packaged power industry through its Power Source
Division.
4. TAFE has also diversified into Engineering plastic and production of tools and dies for
this industry.
5. TAFE’s vision is not justwishfulthinking but based on recognized engineering,
marketing and financial strengths, builtup over the past four decades.
6. TAFE has in- housefacilities for the manufactureof hydraulic pumps and gears for
tractors. A related facility for the manufacturing of panel instruments, not only for
captive use but also for the growing automobile industry in India is an integral part of
the company.
7. To achieve the distinction of the first choice among the farming community of India
and ensurea growing presencein international markets through setting leadership
standards of performanceand customer care in the agricultural machinery business
TMTL
Amalgamations group
TAFE
TMTL
Tractor division Engine division Transmission
Bhopal Alwar division, Parwanoo

TMTL- A wholly owned subsidiary of TAFE (Tractors and Farm Equipment). TAFE is a
unit company of the amalgamation group one of India’s largestlight engineering group
with diverseinterests in diesel engines, auto mobile components, tractors and related
farmmachinery, lubricants panel instruments, hydraulic pumps, engineering tool,
storagebatteries, engineering plastics, automobile franchises and printing apart from
interests in agribusiness, book selling& publishing . The group’s leadership technology
built on foreign know how has been nurtured through indigenous efforts.
TMTL has in three divisions in India –
 Tractor Division, Bhopal –
Manufactureand Assembly of Tractors.
 Engine division, Alwar –
Manufactureand Assembly of Auto & Stationary Engines.
 TransmissionDivision, Parwanoo –
Manufactureof various Transmission components
like Spur Gears, Helical Gears, Spline Shafts, Crown Wheel Pinion, and Cam Shaft.
Tractor division at Bhopal viz. Eicher tractors. Eicher tractors a pioneer in tractor
manufacturing in India rolled out its first Indian tractor in 1959 with the collaboration of
gerb-eicher, Germany in 1960. The other group company TAFEtoo is amongstthe oldest
tractor manufacturer in India and is manufacturing and selling Ferguson and TAFErange
of tractors. TAFEand TMTL as a group is the second largest tractor manufacturein India.
Jointly more than 25 tractor models and 100 variants. Which is the largest rangebeing
offered by any tractor manufacturer in India?
Eicher India has manufacturing and design facilities in mandideep in Madhya Pradesh and
producing 13 base models ranging from 24HP to 50HP.
Eicher range of tractors enjoys unique advantages in terms of phenomenal fuel efficiency,
Its easy maintenance, higher pulling capacity, reliability and suitability for farm and
commercial applications.

EICHER ENGINE ALWAR
 Established in 1982
 technical tie-up:-
 Technology transfer from Ricardo of UK for developing air-cooled engines.
 Technology transfer from SISU(VELMET) Finland, for higher horsepower
tractors.
 Eicher Engines :- some awards and recognition
TECHNOLOGY IN EICHER:-
Eicher has state of art Productdevelopment centre at Alwar facility, which has CREO,
ANSYS, Auto CAD, Adams, Hyper mesh work stations, simulation rings, mechanicalengine
test beds and mock shop for developing new products. The plant has assembly lines, Co-
ordinate Measurement Machines and conveyers for various productlines. Eicher puts a
lot of emphasis on technology up gradation of its servicenetwork as well. Company uses
ITas a business excellence and its home portal EPIC is widely used for all in-housedaily
management progress of information sharing. Leaveplanning. Performanceappraisal and
progress tracking etc. ERP package of SAP was established in 1999, which helps smooth
transactions in supply chain management processes from supplier raw material planning
to tractor delivery at sales outlets and demand forecasting.
1994-95 Certificate of merit for productivity performance awarded by
national productivity council
1996-97 Certificate of merit for productivity performance awarded by
national productivity council

PRODUCT RANGE
 Tractor models :
• 241xtrac - 24hp tractorsingle cylinder air cooled
• 242xtrac - 24hp tractorsingle cylinder air cooled
• 312SDI- 30hp tractor two cylinder air cooled
• 333SDI- 30hp tractor two cylinder water cooled
• 364SDI- 35hp tractor two cylinder air cooled
• 368SDI- 35hp tractor three cylinder air cooled
• 380SDI- 35hptractor three cylinder water cooled
• 485SDI- 42hp tractor three cylinder air cooled
• 480SDI- 42hp tractor three cylinder water cooled
• 5150SDI- 47hp tractorthree cylinder water cooled
• 5660- 52hp tractor three cylinder water cooled
 stationary Engines:
 222ES/222HS - 18hp single cylinder 1500rpmrating
 322ES - 24 hp two cylinder 1500rpm rating
 422ES - 34hp three cylinder 1500rpm rating

EICHER ENGINES PRODUCT
222es-agro-engine 222-esg-genset-engine
321es-agro-engine 421es engine

422es-agro-engine 422-es-genset-engine
461-es-genset-engine 881esg-genset-engine
Eicher-diesel-generator (15, 20, 25, 30-35, 40-45, 65.5KVA) GENSET

Double-cylinder-air-water cylender-1water cooled engine
-Cooled-diesel-engine
Full form Related of engine model
 HS- Handle Start
 ES- Electric Start
 ESG- Electric Start Generator
 ESU- Electric Safety Unit
 GCU- Gen set Control Unit
 CPCB- Central Pollution Control board
 EGR- Exhaust Gas Recirculation
 ED- Engine Derated
 EDD- Engine Double Derated
 KVA- kilo Volt Ampere
 T.C- turbo Charger
 I.C- Inter Cooler

Process Flow Chart
RAW MATERIAL IN THE FORM OF CASTING AND FORGING SHALL BE
INSPECTED FOR PARAMETER AS PER SPECIFICATION / DRAWING AND
SENT TO STORE COMPONENTS LIKE PISTON, LINER, BLOWER SHAFT
ETC. SHELL BE SENT FOR SUB-ASSEMBLY PRIOR TO ITS PERFORMANCE
AND THEN PAINTED. THE PAINTED ENGINE IS SUBJECTED TO PRE-
DISPATCH INSPECTION PRIOR TO ITS DISPATCH AS FINAL PRODUCT.
IncomingMaterial
Receipt & Inspection
Store
Engine Assembly
Engine Testing
Engine Painting
Pre –dispatch Inspection
Dispatch

DEPARTMENTS IN EICHER ENGINES, ALWAR
 PRODUCT DEVELOPMENTCENTER
 FINANCE AND ACCOUNTS DEPARTMENT
 SALES AND MARKETING DEPARTMENT
 MATERIALS/VENDOR DEVELOPMENT
 STORE DEPARTMENT
 QUALITY ASSURANCE DEPARTMENT
 DESIGN RELEASE DEPARTMENT
 PRODUCTION DEPARTMENT
 MAINTENANCEDEPARTMENT
 ENGINEERING & PROJECTS
 HUMAN RESOURSES DEPARTMENT

AN OVER LOOK INTO THE SYSTEM OF EICHER ENGINES
There are following basics departments in Eicher Engine
1. PRODUCT DEVELOPMENT CENTER
This department is responsiblefor designing the products to be manufactured
by the different vendors.
2. FINANCE AND ACCOUNTS DEPARTMENT
This department is responsiblefor all the financial transforms thatare
carried out in the company such as payments for all the incoming material, salaries
of all the employees, all the records for expenditures and credits to the company
are maintained by this department.
3. SALES AND MARKETING DEPARTMENT
This department is responsiblefor consolidating the position of the company
in the market every year. Every year these people get somenew strategies so as to
increase the shareof the company in the market most of the sales of the company
are dependent on the working of this department thus being one of the most
important departments.
4. MATERIALS/VENDORDEVELOPMENT
This department is responsiblefor all the incoming material from the vendor.
This department is further divided into two departments.
a) Vendor Development
All the new samples and in fact all the new components are developed by
this department. All the components developed are not consumed as a part
of the regular production but implemented as a trial only and consumed in
regular production only after these components are regularized.
b) Purchase Department
This department is responsiblefor all the incoming material broughtin that is
used in regular production.

5. STORE DEPARTMENT
This department is responsiblefor the handling of the incoming material, supplying
the material on to the line and also the dispatch the rejected materials back to the
vendors.
6. QUALITY ASSURANCE DEPARTMENT
This department is responsiblefor overall quality control of the incoming
components and assuranceaboutthe quality of the engines to the customer.
Quality can be defined as “fitness for use” when we talk of quality it means that
productshould be fit for use and it is the user who judges and decides what
qualities he wants in the product.
The Quality Characteristics Can Be Grouped Into Four Categories:
a. Quality of design
b. Quality of conformance
c. Availability
d. Customer service
The Various Sub-Departments Of Quality Assurance Department Are:
a. Metallurgical lab
b. Standard room
c. Development cell
d. Receipt quality control
e. Manufacturing quality control.
Sample validation:-
If there are some changes to be made or any new component is to install a lot of five
samples is to be broughtto the sampleroom for verification purposes. Then the sample is

Passed on depending upon its department purposeis to check the components of new
vendor.
The objectives of sample validation department are:
 To assurethe dimensional and other characteristics of new sample are conforming
to the specification.
 To make quality standards along with materials department to ensure the
characteristics of components over long period of time.
Metallurgical lab:-
This lab has all facilities to determine the chemical composition of the raw material
used for the production of various components. This lab includes universaltesting
machine, Rockwell machine, brinell hardness tester, rubber testing machine, chemicals
for determine the microstructureof the raw material, rubber tensile testing equipment.
The objectives of metallurgy lab:-
 To ensureall components should be free from any sortof non-conformance
related to physicalchemical aspects per relevant standards. To ensure the
quality of paints rubber items.
Standard room:-
This department houses all the measuring instruments and their records. Itis a fully air
conditioned room with dust free environment. The roomis specially made dustproof for
avoiding any measurementanomalies. CMM machine is installed here which is used to
check the components for better accuracy.
Objectives of Standard room:-

 To performcalibration of the various instruments in various department.
 To demonstrate the confidence level of measurementsystem to the
customer.
 Gauge planning and procurement from the vendor for calibration.
7. DESIGN RELEASE DEPARTMENT:-
This department deals with productdevelopment of new tractors as was Valtra
when it was developed last year. Basically this department coordinates between
design and various divisions.
Objectives of design release department:-
 New design implementation.
 To coordinate different department while new design is to be
implemented.
 Review of components according to quality aspects and design review.
Receipt quality control:-
Receipt quality control (RQC) may be defined as the sum of the measurement taken by
the receivers to assurethe quality or material offered by vendor. This development
receives the components fromthe vendor and assures mainly the dimensional aspectand
also the appearance of the component. This department has a very large list of gauges
and instrument, which are duly calibrated according to date; Adherence and tractability
to the is there.
The clearing of components includes evaluating the samplesize from each lot; the
components are checked for various aspects and then send for confirmation or rejection.

Objective of Receipt quality control (RQC):-
 To assurethe quality of a particular unit or group of units submitted for
acceptance.
 To assurequality characteristics over the long term will meet with the quality
standards.
The Receipt quality control (RQC) department is sub divided into four sections
as materials there are
I. Sheet metal
II. Casting
III. Forging
IV. Bar stock
Manufacturing quality control:-
The department deals with the manufacturing quality. To ensurethis quality, various
audits are conducted like FIFO (firstin firstout), torquing, functional audit, settings and
various alignments, bearing, final productaudit etc.
 Judging the conformity of the established standard and taking suitable action when
deviation is noted.
 To assurethat these standards areimplemented by conducting daily audits and
upgrading the standards as and when required.
8. PRODUCTION DEPARTMENT:-
This department is responsiblefor carrying outall the assembly operations. This
department is further sub-divided into some of the parts as per different assembly
lines such as hydraulics assembly line, transmission line, pre-painting line, paint
kitchen, postpainting line, PDI etc.
a. Maintenance department
b. Store

a. Maintenance department:-
For regular and preventmaintenance of machines and other equipment used
for assembly this department provides its services.
b. Store:-
Store assures regular rand continuously supply to avoid line stopping. All the
materials purchased arestored here systematically and items that can be rusted
are applied with rustpreventive oil once in a week and in season in a week.
9. ENGINEERING & PROJECTS:-
This department deals with the shop floor problems and identifies the potential
areas for improvementby studying the existing facilities which leads to layout
modification, Structuremodification and also lead to the designing of trolleys and
tackles. It also participates in discussion for selection and finalization of new
machine tools, which involves the studying of tooling requirement and then makes
the tooling available and establish them.
Capacity enhancement like building new storages, new assembly areas, and offices
as per the futureplan of the plant is also one of the works doneby department.
Nearly all kinds of machines, presses, wrenches etc are handed over by engineering
department.
10. MAINTENANCEDEPARTMENT:-
This department is responsiblefor carrying outall the maintenance work to be
carried out in the plant. Any kind out of repair work or maintenance such as
electrical maintenance, this department carries out working of equipment on the
assembly line etc.

11. HUMAN RESOURSES DEPARTMENT:-
This is the most important department of any organization. As we all know that 3
M’s are most vital for any production unit. These 3M’saremen, materials and
machines, out of all the, men or human resourceis the most complicated or
important resourcefor any organization, the department which performs all the
functions relating to the human resourceis known as HUMANRESORCE
MANAGEMENT .
Human resource department is divided into three parts:
 CorporateHR
 Plant HR
 Marketing HR
12. ADMINISTRATION:-
The department look for the reception of the company, Security of the plant,
greenery of the plant, transportfacilities etc.
13. CENTRE OF EXCELLENCE:-
The function of the department is creating the work culturein the company. Look
for the certification of the company. Currently haveTS 16949:2002and ISO
14001:2004and going for the OHSAS 18001:2007and the vision of the department
is to get Deming prizein 2016.

MATERIALS
Material department is the heart of any assembly unit. This department requires
people with extreme passion for their work and those who can get things done at
the lowestcost. The basic function of material department is to providethe
production unit with all the components required for assembly. Peoplein this
department have to make surethat whatsoever material is required for day’s
production is provided. At Eicher thousand of componenthas to be provided from
a network of around 600 vendors from differentstates. Material department
usually works overtimeto see that they get material from this vastvendor network
despite rain, strikes and delays in transportation due to breakdown of transport
vehicles etc. here everybody work as a partof a team becauseeven if a single
component is not in adequate quantity then despite the presence of all other
components line will stop and this will not be the failure of an individual but failure
of materials department as a whole.

PROJECT
Metallurgical Testing of
Valtra Engine Component

Metallurgical lab:-
This lab has all facilities to determine the chemical composition of the raw material
used for the production of various components.
This lab includes
 Rockwell hardness tester
 Universal testing machine
 Brinell hardness tester
 Rubber and plastic tensile tester
 Chemicals for determine the micro-structure of the raw material
The objectives of metallurgy lab:-
 To ensureall components should be free from any sort of non-conformance
related to physicalchemical aspects per relevant standards. To ensure the
quality of paints rubber items.
Rockwell hardness tester

SCALES:-
Scale Indicator Load
Kgf.
Dial Application
A Diamond 60 Black Carbides, thin steel, shallow case-
hardened steel case carburized
surface
B 1/16”ball 100 Red Aluminum alloys, copper alloys,
unhardened steel etc. in rolled
drawn, extruded or cast metal.
C Diamond 150 Black HCI, pearlitic malleable iron, steel,
deep case, hardened steel, titanium
D Diamond 100 Black Pearlitic, malleable, iron, thin steel
and medium case-hardened steel
E 1/8”ball 100 Red Cast-iron, Al and Mg alloys bearing
metal
F 1/16”ball 60 Red Thin soft sheet, metals annealed
copper alloys
G 1/16”ball 150 Red Cu-Ni-Zn and Cu-Ni alloys,
malleable iron
H 1/8”ball 60 Red Lead, Zn, AL, Mg alloys
K 1/8”ball 150 Red Bearing metals, very softor thin
materials
L ¼”ball 60 Red Plastic materials Bakelite,
vulcanized fiber
M ¼”ball 100 Red Nylon, polystyrene,
P ¼”ball 150 Red
R ½”ball 60 Red Rigid sheet and plate materials
used for electrical insulation are
tested by M&L scales.
S ½”ball 100 Red When the “spring constantor
correlation factor is included in the
test procedureonly R scale is used.
V ½”ball 150 Red

Rockwell hardness tester:-
The Rockwell scale is a hardness scalebased on indentation hardness of a
material. The Rockwell test determines the hardness by measuring the depth of
penetration of an indenter under a large load compared to the penetration made
by a preload. There are different scales, denoted by a single letter, that use
different loads or indenters. The resultis a dimensionless number noted as HRA,
HRB, HRC, etc., where the last letter is the respective Rockwellscale.
When testing metals, indentation hardness correlates linearly with tensile strength.
This important relation permits economically important nondestructivetesting of
bulk metal deliveries with lightweight, even portable equipment, such as hand-held
Rockwell hardness testers.
The determination of Rockwell hardness of material involves the application of
a minor load followed by a major load. The minor load establishes the zero
position. The major load is applied, and then removed while still maintaining the
minor load. The depth of penetration from the zero data is measured from a dial,
on which a harder material gives a higher number. That is, the penetration depth
and hardness areinversely proportional. The chief advantageof Rockwell hardness
is its ability to display hardness values directly, thus obviating tedious calculations
involved in other hardness measurementtechniques.
Itis typically used in engineering and metallurgy. Its commercial popularity
arises fromits speed, reliability, robustness, resolution and smallarea of
indentation.
In order to get a reliable reading the thickness of the test-piece should be at least
10 times the depth of the indentation. Also, readings should be taken from a flat
perpendicular surface, becauseconvex surfaces givelower readings. A correction
factor can be used if the hardness of a convexsurfaceis to be measured.

Work instructionfor Rockwell for Rockwell hardnesstesterin“A”,”B”,”C”Scale
Choice of loads & indenter for
various hardness tests.
60kgf 100kgf 150kgf
Rockwell hardness value in scale type
of indenter
HRA
Diamond
HRB
Ball1/16”
HRC
diamond
Testing materials Hardness over 60HRC,
case depth up to 1.00
mm
Softer, middle
hardness or
unquenched
steel parts
Any type of
heat treated
steel part/
chilled area of
cast iron
Measuring tolerances 20-75HRA= ±2
75-88HRA=±1.5
20-45HRB=±4.0
45-80HRB=±3.0
81-100HRB=±2.0
20-
63HRC=±1.5
Procedure:-
Rockwell hardness tester

1) A. initial load 10kg
Remark: - check the knurled knob, it should be on 10.
B. actual weights applied marked as
Remark: - 60kg for HRA
100kg for HRB
150kg for HRC
C. indenter
Remark: - diamond for the HRA and HRC scale& ball dial 1/16” for HRB
scale.
D. hardness scale
Remark: - outer black dial reading for HRA & HRC.
2) Keep the master block/ component on table of hardness tester.
3) Making sureto chooseright penetrator.
Remark: - diamond indenter for the HRA and HRC scale and
Ball dials 1/16” indenter for HRC scale.
4) Miner load apply on master pcs by 2.5 rotation of dial or up to 3 noc indication mark of
dial (red dot)
Remark: - during minor load apply; the lever should be on inspector
side.
5) Rotating the working plate slowly to supportup the penetrator till small finger of
indicator points at the red mark, the big finger turns 3 circles and stop vertically on the
zero reading of the dial.
Remark: - ensure small finger stay on 3 (red marked) & bid finger stay
on 0 (rounded black scale)

6) Turning the test force knob to test forcethru rotating hydraulic lever.
7) Pulling the loading handle to apply main test force as arrow direction, at this moment
the big finger of dial indicator rotates anticlockwise.
Remark: - making surethat lever position should be oppositethe inspector
after applied the test force (60kg for HRA, 100kg for HRBand 150kgf HRC.)
8) Hold loading handle at this stage up to dial Niddle stop.
9) Pushing back the unloading handle to release the main test forceafter the big finger of
indicator stops clearly.
Remark: - leaver position should be on inspector side.
10) Waiting for big finger fixed on one data and getting the hardness valueof the
standard block / components.
Remark: - getting the hardness valueas mentioned:-
1. For HRA/HRC= full round black colored scale.
2. For HRB= full round red colored scale.

Universal testing machine:-
A universaltesting machine (UTM) also known as a universal tester materials
testing machine or material test frame, is used to test the tensile strength and
compressivestrength of materials. The “universal” part of the name reflects that it
can performmany standard tests on materials, components, and structures (in
other words, thatit is versatile).
Components:-
 Load frames – Usually consisting of two strong supports for themachine
some small machine havea single support.
 Load cell – A force transducer or other means of measuring the load is
required. Periodic calibration is usually required by governing regulations or
quality system.
 Cross head – A movable cross head (crosshead) is controlled to move up or
down. Usually this is at a constant speed: sometimes called a constantrate of
extension (CRE) machine. Some machine can program the crosshead speed
or conductcyclical testing, testing at constantforce, testing at constant
deformation, etc. electromechanical, servo-hydraulic, linear drive, and
resonancedriveare used.
 Means of measuring extension or deformation many tests require a measure
of the test specimen to the movement of the cross head. Extensometers are
sometimes used.
 Output device – A means of providing the test result is needed. Some older
machines have dial or digital displays and chart recorders. Many newer
machines have a computer interface for analysis and printing.
 Conditioning – Many tests requirecontrolled conditioning (temperature,
humidity, pressure, etc.). Themachine can be in a controlled room or a
specimen for the test.
 Text fixtures, specimen holding jaws, and related sample making equipment
are called for in many test methods.

Use:-
The setup and usageare detailed in a test method, often published by a standards
organization. This specifies the sample preparation, Fixturing, gauge length (The length
which is under study or observation), analysis, etc.
The specimen is placed in the machine between the grips and an extensometer if required
can automatically record the change in gauge length during the test. If an extensometer is
not fitted, the machine itself can record the displacement between its cross heads on
which the specimen is held. However, this method not only records the change in length
of the specimen but also all other extending/elastic components of the testing machine
and its drivesystems including any slipping of the specimen in the grips.
Once the machine is started it begins to apply an increasing load on specimen.
Throughoutthe tests the controlsystem and its associated softwarerecord the load and
extension or compression of the specimen.
Machines rangefromvery small table top systems to ones with over 53MN
(12 million Ibf) capacity.
Procedure for checking of tensile strength by UTM40
Description of arrangement:-
S.no. Technical data UTM4 UTM10 UTM20 UTM40
1 Measuring ranges 4ton 10tons 20tons 40tons
2 Graduation(min.) 8kg. 20kg. 40kg. 80kg.

Universal testing machine
Steps:-
1) Firstof all ensurethe zero setting by Appling the hydraulic load without
components.
Remark: - the load- indicator zero and the plot-load-axis zero, if applicable,
should be set before the specimen is placed in the grips. Zeroes should never be
reset after the specimen is in place.
2) Select the weight as per section of tonnage.
Remark:-
4TON– only pendulum
10TON- only A including pendulum
20TON- only A+B including pendulum
40TON- A+B+C including pendulum.
3) Select the jaws.
Remark:-
Serration jaws- for sheet metal
Round serration jaws- for smallfasteners
Holding jaws- for CI rods & long fasteners

4) Specimen for tensile strength beforestrength beforeto put into machine we
should have the following values of specimen :-
i. Cross section area
ii. Gauge length
Remark:-
Checking the tensile of fasteners, wecan usethe made out fixture
according to their size.
4a) following formula is used to calculate the cross section area and gauge length
Cross section area
 Round bar = πr2
 Squarebar = b*t
 Fastener (which broken on thread) = 0.7854(D-0.9382P)2
Where
Π = 3.14, r= radius, b = breath, t = thickness
Gauge length:-
Lo = 5.65*A where A = cross section area
THREAD SIZE CROSS SECTION
AREA
M14*1.5 124.49mm2
M12*1.75 84.30mm2
M12*1.50 88.10mm2
M12*1.25 92.09mm2
M10*1.50 57.95mm2
M8*1.25 36.64mm2
M6*1.0 20.12mm2
5) Specimen alignment in fixture, should be proper and in centre.

Remark:-
The specimen is placed in the grips and is secured by closing the grips.
6) After the aboveset up, ensurethe proper straightening / tightened the specimen
in jaw.
For this the both valveshould be on open condition.
Remark:-
Rotate the value anti clockwiseto open than operate the push button
for upward / downward direction for proper tightening the specimen.
7) Next both valves should be properly closed by moving the clockwise direction.
Than push the hydraulic pressureswitch on for applying the load.
Remark:-
Rotate the valveclockwiseto close.
8) Than open the hydraulic pressurevalveslowly by operating the valveon anti
clockwise, when hydraulic pressureis increasesimultaneously load applied on
specimen.
Remark:-
Hydraulic pressureshould beon very slowly until you didn’t get the actual
load of fracture.
9) When a specimen is subjected to an external tensile loading, the metal will undergo
elastic and plastic deformation. Initially, the metal will elastically deform giving a
linear relationship of load and extension. These two parameters are then used for
the calculation of the engineering stress and engineering strain to give a
relationship as illustrated in given below figure and using equations to get the
results.
10) After fracture, the maximum load shall be recorded and the diameter at
point of fracture
Tensile strength = p/A0
(Where p = maximum tensile load & A0 original cross section area).

Percentage elongation = [(lo’-lo)/lo] x100
(where lo’ is final gage length after fracture)
Percentage reduction in area= [(Ao - Ao’)/Ao] x100
(where Ao’ is final reduced cross sectional area after fracture)
Yield strength = load at yield strength/originalcross section area.

Brinell hardness tester:-
The brinell method is suitable for testing the hardness of softmetals (light metals, lead,
and tin) through to hard metals, such as steel and iron.
Brinell testing of a material with differentball diameters and test forces mustbe
conducted within the same force-diameter index in order to enable direct comparison of
the measured hardness values.
The brinell methods grouped by force-diameter index, the association hardness rangeand
recommended applications (materials). The higher the load factor, the harder the metals
that can or should be tested with the methods within this force-diameter index. The most
common force-diameter index is HBW30. Brinell method HBW30 is used for testing hard
metals, such as steel and iron.
In the brinell method, the indents must be positioned such that there is sufficient
clearance fromthe specimen edge and between this individual indents. The minimum
values to be observed in accordancewith the standard can be found.
The specimen must be thick enough for the indent not to cause any visible deformation
on the underside of the specimen (supporting surface).
According to the standard, this means that the specimen must be at least at times thicker
the then indentation depth of the brinell ball. The indentation depth can be estimated
fromthe expected hardness value, which in turn depends on the averageindent
diameter. The minimum specimen thickness can therefore be derived as a function of the
averageindent diameter and the ball diameter of the brinell indenter. A detailed from
Which the minimum specimen thickness can be read correspondingly for brinellcan be
found by table.

In the Brinell hardness test, an optical method, the size of indentation left by the indenter
is measured. In contrastto the likewise optical Vickers method, which involves a pyramid-
shaped indenter being pressed into a specimen, the brinell method uses a spherical
indenter.
The larger the indent left in the surfaceof a work piece (specimen) by the brinell indenter
with a defined ball diameter and a defined test force, the softer the tested material.
In order to determine the Brinell hardness (HBW) according to ISO6506. Thespherical,
hard metal (tungsten carbide) indenter is pressed into a specimen (work piece) with a
defined test load (between 1kgf and 3000kgf). The Brinell hardness (HBW) results from
the quotient of the applied test force (F) in Newton’s (N) and the surfacearea of the
residualindent on the specimen (the projection of the indent) after withdrawing the test
force. To calculate the surfacearea of the residualspherical indentation, the arithmetic
mean (d) of the two perpendicular diagonals (d1 and d2 in mm) is used, becausethe base
area of brinell indents is frequently not exactly round.
d1 F d2
Ø𝑫

HBW = constant* test force (F)/surface of the indentation =
0.102 * 2F/πD2
(1 − √1 − 𝑑2/√𝐷2)
Where
d= d1+d2/2 (average indentation diameter)
WORK INSTRUCTION FOR BRINELL CUM VICKERS HARDNESS TESTER
The ball diameter and load stages should be used in the Brinell hardness tester
Ball dia
(in mm)
Load stages
30D2
10 D2
5 D2
2.5 D2
1.25 D2
0.5 D2
10 3000 1000 500 250 125 50
5 750 250 125 62.5 31.25 12.5
2.5 187.5 62.5 31.25 15.625 7.8125 3.125

Following load stages should be used in the Brinell hardness
test.
S.no. Material Hardness
range
Load
range
1 Soft iron,steel casting,malleable iron 68-500HB 30 D2
2 Light alloy,casting & forging alloy,dia-castingAlloys
,Al-alloy,copper, brass,bronze, nickel
23-315HB 10 D2
3 Pure aluminum, magnesium, zinc,cast brass 12-158HB 5 D2
4 Bearingmetals 7-78HB 2.5 D2
5 Lead, tin,soft solder 4-39HB 1.25 D2
6 Soft, metal at elevated temperatures 2-15HB 0.5 D2
BRINELL CUM VICKERS HARDNESS TESTER

Process-:
1. In startwe check the material and hardness valueon drawing/specification.
Remark:-
Based on material and hardness valueselect the indenter and load.
Ball dia. = 2.5mm
Diamond indenter = 1360
2. Select the load frompush button (on right hand side, mentioned the load on push
button).
Remark:-
2.5dia indenter used for HB hardness & diamond pyramid indenter used for
Vickers hardness.
3. Place the object / components on Supper.
Remark:-
Be remember the object/ master/ components should be parallel to the
object, otherwise ball/ indenter may be destroy/broken.
4. Switch on light by the left hand knob, than focus the object.
Remark:-
Remember the object image should be clear on screen. Check the measuring
scale also be clear visible on screen.
5. Appling the load by push button, lever moves to upward direction automatically.
Remark:-
Wait 30sec. for proper impression of ball indenter on object.
6. Down the lever slowly to unload the weight, than you found that the indenter is on
starting condition.
Remark:-

Wait 10sec. for auto focusing of indentation.
7. Check on screen, you found the indentation mark & measuring the length of dia /
squareby the vernier scale in the screen.
Remark:-
Circle indention found by the ball indenter and squareindentation mark by
the diamond pyramid.
8. Length converts to hardness by the chart near affix the machine.
[Mark sure to take at least 03 reading on master/ standard block to
validatethe hardness tester. If the master reading match with
standard than we should have to start the work on hardness tester.
If not than accommodate the difference value on object hardness. ]

MICROSTRUCTURE:-
Microstructureis small scale structureof a material, defined as the structureof a
prepared surfaceof material as revealed by a microscopeabove25xmagnification.
The microstructureof a material (such as metals, polymers, ceramics or composites)
can strongly influence physicalproperties such as strength, toughness, ductility,
hardness, corrosion resistance, high/low temperaturebehavior or wear resistance.
These properties in turn govern the application of these materials in industrial
practice.
Microstructureat scales smaller than can be viewed with optical microscopes is often
called nanostructure, whilethe structurein which individual atoms are arranged is
known as crystalstructure. The nanostructureof biological specimen is referred to as
ultra structure.
MICROSTRUCTURE CHARACTERIZATIONS:-
To quantify micro structuralfeatures, both morphologicaland material property must
be characterized and material property mustbe characterized. Imageprocessing is a
robusttechnique for determination of morphologicalfeature such as volume fraction,
void, crystalorientations. To acquiremicrographs, optical as well as electron
microscopy arecommonly used. To determine material property, Nano indentation is
a robusttechnique for determination of properties in micron and submicron level for
which conventional testing are not feasible. Conventional mechanical testing such as
tensile testing or dynamic mechanical analysis can only return macroscopic properties.
However, Nano indentation can be used for determination of local micro structural
properties of homogeneous as well as heterogeneous materials.
OPTICAL:-
When a polished flat sample reveals traces of its microstructure, it is normalto capture
the image using macro photography. Moresophisticated micro structureexamination
involves higher powered instruments: optical microscopy, electron microscopy, and x-
ray

Differenceand so on, some involving preparation of the material sample (cutting,
microtome, polishing, etching, vapor-deposition etc.). These methods are known
collectively as metallographic as applied to metals and alloys, and can be used in
modified formfor any other material, such as ceramics, glasses, composites and
polymers.
Two kind of optical microscopeare generally used to examine flat, polished and
etched specimens: a reflection microscopeand an inverted microscope. Recording the
image is achieved using a digital camera working through the eyepiece.
 To study the micro structure of the cylinder clamping
screw.
Steps-:
1) Firstof all taken a cylinder clamping screw and cut the requirement position.
2) After the cut a piece providea finishing to the twin wet belt grinder and
remove the rough surface.
3) Use the micro sampling mounting fixture and put the sample in the mounting
fixture cavity and use to grease to Easley removethe particle and use to the
white plastic powder (cold setting compound) and liquid (cold setting
compound) as a equivalent amount and put the 15-20min.
4) After that use the emery paper for different sizeand remove the fine
abrasiveparticle fromthe piece.
Grain sizefor emery paper
(Grade-220, grade-4/0, grade-3/0, grade-2/0, grade-1/0)
5) After that applied the etching process.
Remark-:
Before etching, the polished specimen is thoroughly washed in running
water. Then the etching is done either by
 immersing the polishing surface(of the specimen) in the etching
reagent or by

 Rubbing the polished surfacegently with a cotton swab wetted with
the etching reagent.
After etching, the specimen is again washed thoroughly and dried.
Etching Reagents for Microscopic Examination
S.
no
Type of Etching Composition Uses
1. Nital .Cone, Nitric acid
.absolutemethyl
alcohol
2CC
98CC
For etching steels, gray cast
iron & black heart malleable
2. Acid
ammonium per
sulfate
.hydrochloric acid
.ammonium per
sulfate
.Water
10CC
10gms
80CC
For etching stainless steels.
3. Ammonia
Hydrogen
Peroxide
.ammonium
hydroxide(.0880)
.hydrogen
peroxide(3%solution)
.water
50CC
20-50CC
50CC
The best general etching
etchant for copper, brasses
and bronzes.
4. Dilute hydro-
fluoric acid
.hydrofluoric acid
.water
0.5CC
99.5CC
A good general etch-ant for
Al and its alloys
5. Keller’s
reagent
. hydrofluoric acid
.HCL
.HNO3
. water
1CC
1.5CC
2.5CC
95CC
For(immersion) etching of
Duralumin type alloy
6. Mixed nitric
and acetic
acids
.Nitric acid
.glacial acetic acid
50CC
50CC
A good general etch-ant for
Al and its alloys
6) After that etching process we use the microscope to saw that
micro-structure of the cylinder clamping screw.

Process flow chart of micro structure
Cut The Piece
Remove Abrasive Particle
Use A Micro-mounting
Press Fixture
Remove Abresive Particle
Through Embery Paper
PolishingThe Sample
AppliedEtching Process
Microscope Use To Saw
The Micro Stracture

Dye Penetrant Inspection-:
Dye penetrant inspection(DPI),or also called liquid penetrant inspection(LPI) or penetrant
testing(PT), is a widely applied and low post inspection method used to locked surface breaking
defects in all non-porous materials(metals, plastics, or ceramics ). Penetrant may be applied to
all non-ferrous materials and ferrous, although for ferrous components magnetic-particle
inspection is often used instead for its sub-surface detection capability. LPI is used to detect
casting, forging, and welding surface defects such as hairline cracks, surface porosity, leaks in new
products, and fatigue cracks on in-service components.
PRINCIPLE -:
DPI is based upon capillary action, where low surface tension fluid penetrants into clean and dry surface-
breaking discontinuities. Penetrant may be applied to the test component by dipping, spraying, or
brushing. After adequate penetration time has been allowed, the excess penetrant is removed and a
developer is applied. The developer helps to draw penetrant out of the flaw so that an invisible
indication becomes visible to the inspector. Inspection is performed under ultraviolet or white light,
depending on the type of dye used- fluorescent or non-fluorescent visible.
Steps:-
 Step:-1
Applied FC911/2 red penetrant (solventremovable)
 Step :-2
Applied FC711/2 green penetrant (solventremovable)
(Remove red penetrant)
 Step:-3
Applied FC811/2 wet developer
After applied the wet developer then inspection visible
If any defect found then reject the product.
Test component:-
Dogbon (125kva 4cylinder)

Millipore:-
Millipore may refer to:-
 Millipore Corporation, a biosciences company.
 Millipore filter, Nucleopore filter, nitrocellulose or polycarbonate membrane
filters with a pore size5 µm.
 Millipore chamber, or Millipore diffusion chamber, a round- shaped chamber
widely used for in vivo research, sealed at each end with a cellulose cell-
impenetrable filter to permit the growth of transplanted cell or tissue, while
allowing nutrients through

Procedure:-
 First pass the part from the trichloroethylene. The trichloroethylene
will take the contamination or the surface deposits with and the
collect it in to a collector.
 Then the contamination trichloroethylene from the Millipore
apparatus machine from the Millipore filter and find the
contamination.
 Then dry the contamination up to the temperature of 60-800
c
[They fixed a particular amount of contamination say
5Mg/part. They fixed a particular amount of contamination is
more than that the piece will be rejected]

s.no
.
I code Component Name Material Hardness
1 1670426 Cyl. Head Screw (12*140) Grd12.9 39-44HRC
2 1670499 Screw M12*142 For Cyl. Head Grd12.9 39-44HRC
3 1671339 Washer For Oil Pump Fe52c 30-35HRC
4 1670610 Adjusting Screw C45kv HRC55-60
5 1670736 Tappet Chilled casting HRC50 min.
6 93181352 Drive Shaft For Hyd Pump 20Nicrmo5-02 400-450HB
7 93184018 Exhaust Manifold (45kva & 62.5kva) SG-450/10,
ES01IT18:1
190-240BHN
8 1671996 Thermostat Housing GRSH 195 sfs4855 HB170-220
9 1671080 Front Cover M/C GRSH 195 sfs4855 HB170-220
10 1671017 Gear Housing M/C(Valtra) GRSH215 FG260 190-240BHN
11 93180268 Exhaust Manifold(Auto) FG260 ES01IT18:1 190-240HB
12 1440020 Cylinder Block Casting-Valtra GRSH-215 SFS4855 BH190-230
13 1440378 Cylinder Head Casting-Valtra GRSH-215 SFS4855 BH190-230
14 93181340 Gear For Fuel Injection Pump 20MnCr5 300HB min.
15 1671327 Gear Wheel (Gear For Oil Pump) 25CrMo4-07240-
290BHN
240-290BHN
16 96132832 Hex Sec Screw M10*30 Sfs2219, 12.9 Grade12.9 39-44HRC
17 1670839 Piston Pin (Auto/30kva/45kva) 17Cr3 55-57HRC
18 93260902 Piston Ring Set Assy. 35-40HRC
19 93178742 Flywheel Bal(Valtra) FG200 ES01IT18:01 160-220BHN
20 2671402 Hex Screw M12*35 Sfs2064 M10.9 Grade10.9 29-34HRC
21 93181364 Gear For Cam Shaft 20MnCr5-02 HRB300 min
22 1670931 Gear For Crank Shaft 40CRMo4 240-290BHN
23 93180554 Piston(Auto/30kva &45 Kva) AlSi12CuNiMg 100-130BHN

24 1670657 Rocker Arm Shaft 25CrMo4-08 240-290BHN
25 1671330 Shaft 21NiCrMo2 55-60HRC
26 1670979 Hub For Crank Shaft 40CrMo4 170-230HB
27 1672770 Valve Seat Steel barØ25
42CrMo4
50-55HRC
28 2671402 Hex Screw M12*35 Sfs 2064 M10.9 Grade10.9 28-34HRC
29 93180104 Oil Sump M/C(Valtra) GRSH215 SFS4855 190-240BHN
30 1670864 Screw For Connecting Rod 40Cr4Mo3 32-36HRC
31 93181443 Crank Pulley 14deg Timing GRSH215 180-240HB
32 1672769 Oil Pressure Valve Steel barØ25
42CrMo4
50-55HRC
33 1670943 Crank Gear 20MnCr5 57-62HRC
34 93180104 Oil Sump M/C(Valtra) GRSH215 SFS4855 190-240BHN
35 2671311 Screw M8*35 Sfs 2064 M8.8 Grade8.8 22-26HRC
36 93178869 Flywheel Casing M/C(Valtra-St) FG220 ES01IT18:1 170-220BHN
37 1670980 V-Belt Pulley(Crank) GRSH215 190-240HB
38 1440100 Cylinder Liner Semi M.Cd Alloy cast iron 230-280BHN
39 93177919 Inlet Valve Seat Assy. HRC40-46
40 16773397 Nut For Crank Shaft C45-08 240-302HB
41 2671311 Screw M8*35 Sfs 2064 M8.8 Grade8.8 22-26HRC
42 1670980 V-Belt Pulley (Crank) GRSH215 190-240HB
43 1570505 Nut M12 Grade12 34-44HRC
44 1670359 Starter Ring CK45 47-53HRC
45 93178092 Valve Guide-Semi Finish 16MnCr5 200-260HB
46 93260100 Injector Washer (2.5mm)$(62.5kva) Cu din1708 43.5-48HB
47 93179710 Bracket(A/C Mtg. Support)$ Fe410WA 170-302BHN

Bearing Housing Cylinder Head
Cylinder Block Casting Gear Housing

Breather Hose
Tappet

Exhaust-Manifold
Gear Wheel Valve-Seat

Thermostat-Housing Oil Pump Assy.
Starter-Clutch-Assy. Piston Ring Set

Piston Pin Piston
Cam Shaft

Cam Shaft
Material composition%
Chilled cast iron Cr- (0.2-0.5)
C- (3.1-3.6) Ni-(0.00-0.40)
Si –(1.6-2.4) Mo-(0.00-0.40)
Mn-(0.5-0.8) S- (0.1max)
p-(0.15max) Co-(0.00-0.60)
Tensile strength-: 25Kg/mm2min
Draftangle-: 2.5$ max
Core structure-: corestructureto be checked at end section of the cam shaft.
Mo, Ni, and Co are optional elements and will be added to the requirement for achieving
desired hardness atcam shaft
Thermostat
Material- assy.
Anchor cap- brass By pass spring- st. steel
Seat- brass By Pass plate- brass
Element- assy. By bass stud- brass
Main spring- st. spring Jiggle pin- brass
Main plate- brass Stem- st. steel
Frame– brass
Crank shaft assy.
Crank pin and gear induction hardness depth:- 2-2.5 , HRC-48-57
 Crank shaft 42CrMo4
 Counter weight for crank shaft

 Counter weight for crankshaft
 Hex screw M12*1.25*35 sfs2219
Main bearing and main bearing grooved
Lining SAE49 (H24)
Steel back SAE1008-1010
Overlay SAE192
Oil Pump Assembly
Parts Material
o.p body Cast iron
Cover Cast iron
Driveshaft Ck-45
Idleshaft EN-353
Drivegear EN-19A
Idlegear EN-19A
Gasket Craft paper
Hex. bolt Std.
Dowelpin Std.
Con Rod Assy. Valtra
Con rod -1
Bush- 1
Screw-2
Nut-2

Spring-:
Specification
Load frequency
Operation temp -40……+1200
c
Winding direction- Right
Wire diameter d=2, 25
Dm (mean coil dia.)= 21, 25
Di(internal)= 19,0 External = 23,5
No of turns = 9min
Valve spring cap
Material - CKtal 15Cr3 or 16MnCr5
Hardness-
Surfacehardness- HV10 450-550
Core hardness max.300HV30
Hardening depth-: 0.2-0.4
Inlet valve
Back 48RC
Front 54RC
Mid 30-40RC
Chrome this length with 0.005-0.010 thick deposit

CONCLUSION
The primary goal of my project is to learn the standard procedure of
‘metallurgy lab’. I have been made to study of property of materials
(component) and its drawing. This study shows that a first check the drawing
and its measurement of the sample product when a measurement dose not
correctly according to drawing then product are rejected and if it is correct
than product are accepted. and after that a sample product is taken from the
store and checks the property of a material. If the sample product is no defect
than the product are accepted and sand to assembly line or other machine
shop, and if the sample product find out any defect then the whole product
are rejected.

References: -
http://www.proplanner.com/documents/filelibrary/do
cuments/papers_case_studies/
http://amalgamationsgroup.co.in/manufacturing-tafe-
motors-tractors-ltd.html

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