INPLANT TRAINING REPORT 2021-22

INPLANT TRAINING REPORT

ON
BAJAJ MOTORS
HANGAL.

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GOVERNMENT OF KARNATAKA

DEPARTMENT OF TECHANICAL EDUCATION BANGLORE-

560001
GOVERNMENT POLYTECHNIC MUNDGOD-581349

CERTIFICATE

It is the in-plant training report on CNC MACHINE TRAINING which is submited by

(NAVEEN SP 167ME17030), (ADITY DS 167ME20002) a student of government
Polytechnic mundgod, in partial fulfillment for the year 2020-2021 is record of students own
Work carried out under my/our guidance. It is certified that all corrections/suggestions
Indicate for internal assessment have been incorparated in the report and one copy of it being
Deposited in the polytechnic library. The in-plant report has been approved as it satisfies the
Academic requirement in respect of in-plant training proscribed for the said diploma

It is further understood that by that certificate the undersigned do not endorse or approve Any
statement made, opinion expressed or conclusion drawn there in but approve the report Only
for the purpose force it is submitted.

Under the guidance of

Mr.Amruth DS ,,,,, BE M TECH

HOD Mr.Mb Huded.

Mr.Amruth DS. PRINCIPAL

Mechanical dept GOVERNMENT POLYTECHNIC

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MUNDGOD

GOVERNMENT OF KARNATAKA
DEPARTMENT OF TECHANICAL EDUCATION
BANGLORE – 56000
GOVERNMENT POLYTECHNIC MUNDGOD -581349,
NORTH CANARA INPLANT TRAINING REPORT
ON
BAJAJ MOTORS HANGAL –581104

SL.NO STUDENT NAME REG NO.

01 NAVEEN SP 167ME 17030

02 ADITYA DS 167ME12002

HOD
AMRUTH BABU DS
MECHANICAL ENGG
GOVERNMENT POLYTECHNIC
MUNDGOD

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 INFORMATION :

MOTORS SERVICE CENTRE

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AKNOWLEDGEMENT

It gave us a great pleasure with knowledge about in plant training “BAJAJ MOTORS
HANGAL” We express sincere thanks to owner and maintenance engineer of “BAJAJ
MOTORS”

We express sincere thanks to our H.O.D AMRUTH DS And Our DEPARTMENT OF

MECHANICAL ENGINEERING, for his suggestion

We immensely thank the working staff of the BAJAJ MOTORS HANGAL - 581104

SL NO. STUDEND NAME REGISTRATION NO.

01 NAVEEN S P 167ME17030

02 ADITYA D B 167ME2002

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CONTENT

SI CHAPTER NAME PAGE NO.

NO

01
Manufacture of Hero Motors vehicles in India 07

02
Main parts Hero Motors vehicles
08-09

03
Main parts of engine 09-10

04 Functions of major components motor engine 11-20

Engine Maintainance
05 • Dis-mounting of engine
• Engine Dis-assembly 21-24
• Engine re-assembly

06
Real image of HERO Motor 24-25

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MANUFACTURE OF HERO MOTOR VEHICAL IN INDIA:

There are many manufactures of motor vehicles in India

These manfactures as follows:

A. Manufacturer of Scooters:

1)Bajaj Auto - Bajaj 150 CKD

2) API - Lambi 150 ,MAC 175
3)Andhra Pradesh Scooters - Vespa PL 150
4) Maharastra Scooters - Priya 150 5)Honda
Motors Co,Ltd. -Active, Dio,etc.
6)Hero Motors -Hero Pleasure Pro
7)Kinetic Engineering -Kinetic 4S
8)Scooters India -Vijay Super 150, Lambretta Cento 100
9)Girnar Scooters - Girnar 150
10)Lohia Machines -Vespa XE 100, Vespa XE 150 etc.

B. Manufacturer of Motor Cycles:

1)Royal Enfield India - Bullet 350,Bullet 500,etc.

2) Bajaj Auto -Bajaj M80, Boxer, etc.

3)Hero Motors - Hero Splender, CD Delux

4) Honda Motors - Honda Shine ,Hnda Unicorn.

5)TVS - Star City

6) Ind Suzuki -AX100

7)Escorts -Rajdoot 350, Rajdoot 175 ,etc.

8)Ideal Jawa -Yezdi 350,Yezdi 250,etc.

9)Karnataka Scooters -Falcon GT50

MAIN PARTS OF MOTOR VEHICALS :

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 Air Filter
 Battery
 Brake Shoe
 Cable Speedometer
 Cam Chain
 Clutch Oil
 Clutch Plate
 Clutch Wire
 Coolant
 Crank Bearing Kit
 Cylinder Kit
 Engine Guard
 Engine Oil
 Fork Right Front
 Handle Bar
 Headlight
 Headlight cover
 Horn
 Ignition Switch
 Indicators
 Kick Lever
 Leg Guard
 Lever complete
 Look Set
 Main Stand
 Meter Assembly
 Mudguard front

 Oil Filter
 Holder
 Piston Ring set
 Rider Foot Rest
 Rider Foot Rest
 Saree Guard
 Shocker Front
 Tail Unit Start
 Tail Panel
 Visor
 Wheel Front

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 Wheel Rear
 Winker Assembly
 Side Panel Set
 Side stand
 Side View Mirror
 Spark Plug
 Speedometer
 Speedometer Kit
 Lock Set
 Main Stand
 Headlight cover
 Horn
 Kick Lever
 Kick starter kit 53. Main Stand

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MAIN PARTS OF ENGINE:

Following are the main parts of the engine.

1) Cylinder Block
2) Cylinder Head
3) Crankcase
4) Piston
5) Piston ring
6) Connecting rod
7) Flywheel
8) Valve
9) Accessories:

 Oil filter
 air cleaner
 automatic choke
 automatic head control
 Spark plug
 ignition device
 carburetor
 vibration damper etc.

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MAJOR FUNCTION OF COMPONENTS OF MOTOR ENGINE:

1)Cylinder Block :

The engine cylinder block is one of the main part of the engine. The engine becomes
the foundation and main stationary body of the automobile engine . The cylinder block serve as support and
enclosure for moving parts.

Generally , the cylinder block is casted from gray cast iron or iron alloyed with others metals such
as chromium ,nickel or molybdenum . The heavy weight engine blocks are made from alluminium

A cylinder block consist of following parts :

 The cylinder in which the piston slide up and down.

 The ports or opening for the valves.
 Thev passages for flow of the cooling water.

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2. Cylinder head:

The top of the cylinder is always covered by a separate cast piece known as the
cylinder head. It is bolted to the top of the cylinder block. It contains the combustion chamber, spark plug
and sometimes valves (in 1 and F-head) are mounted on it. The cylinder head is also provided with passages
for the flow of cooling Water

The cylinder head in generally made up of gray iron or aluminium alloy. It is casted separately from the
cylinder block so that it can be removed easily for cleaning carbon and grinding valves. According to the
valve layout the cylinder head may carry the camshaft, rockers and valves. Water passages are also provided
adjacent to the valve and plug settings.

 Advantage and Dis advantage of alluminium alloy cylinder and cylinder head:

Advantages:
1. High heat conductivity (3 times higher than cast iron).

2. High compression ratio without detonation.

3. Lighter in weight.

4.Exellent cooling capacity while engine running

5. Increased power output.

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6. Low fuel consumption.

7. Quick engine warm up.

Disadvantages :

1. Cost of the engine becomes high.

2. High thermal expansion requires large clearance between piston and cylinder.

3. Due to low modulus of elasticity, it is liable to be crusted out of shape by holding down studs.

4. Sometimes, it is necessary to use cast iron valve seatings and spark-plug inserts.

5. Possibility of sticking of head to the cylinder block due to inter metallic corrosion between alluminium
and cast iron.

3. Cylinder head gaskets:

The gasket is placed between the cylinder block and cylinder head to retain compression in
the cylinder, to prevent the leakage and to ensure metallic tight fit joint as shown in fig. 1.7.
The gasket should be able to withstand high pressure and extreme temperature: Gaskets are
usually coated with a special varnish which melts and seals all the small intersticks of the
head and the block when the engine warms.

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 Functions of Cylinder Head Gaskets :

1. To seal coolant and hot. thin lubricating oil flowing under pressure between the block and
the head.

2 To resist the forces tending to scuff gasket surfaces and preventing proper scaling:

3. To accommodate the uneven expansion and contraction rates in case of bi-metal engines.

4. To resist crushing due to high cylinder damping Jorces unevenly distribute across the

head.

5. To seal the joints between oil pan, manifolds or water pump and the block

 Types of Gaskets Used in Motors Engines :

1.Copper-asbestos gasket.

2. Steel asbestos gasket

3 Steel asbestos-copper gasket

4 Stainless steel gasket

5 Single steel ridged or corrugated gasket.

4. Crankcase:

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Crank case is generally attached to the bottom face of the cylinder block and it also act as a
base pof a engine.The oil pan and the lower part of the cylinder block together are called as
crankcase
The cylinder block and upper half of the crankcase are usually cast as a single unit and sometimes for large
engines they are separately casted. This casting is usually made from ferrous alloy or semosteel to
provide a stronger casting.The use of tougher and stronger material permits thinner casting walls ,
therefore,saving weight and improving cooling. Aluminium is also a potentially attractive material of
crankcase because of its light weight ,good thermal conductivity and good cooling effect.

5.Piston:

Piston can be defined as a disc or cylinder part tightly fitting ang moving within a cylinder
to convert the chemical energy obtained by the combustion of the fuel into useful mechanical power.

 Construction and Working :

Simple construction of the piston as showen in figure. The efficiency and economy of the engine is
primarily depends on the working of piston. Top portion of the piston is called head. Ring grooves is called
skirt.The portions of the piston that separate the grooves are called the lands.Pistons used in some high
powerd engines may have raised dome and these are used to increase the compression ratio and to control
the combustion. The head is provided with valve relief.

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Piston is one of the important parts of a reciprocating engine in which it helps to convert the
chemical energy obtained by the combustion of fuel into useful Mechanical power. The main purpose
of the piston is to provide a means of converting the expansion of gases to the crankshaft via
the connecting rod ,withot loss of gas from above or oil from below .The piston is equipped with
piston rings to provede a good seal between the cylinder wall and piston.

 Functions of the piston :

Following are the functions of Piston.

1. To transmit the force of explosion to the crankshaft.

2. To serve as a guide and bearing for small end of the connecting rod.
3. To reciprocate in the cylinder causing suction , compression , expansion and exhaust stroke.

6. Rings:

Piston rings are fitted into the grooves of the piston to maintain proper scal between the piston and the
cylinder wall. A simple construction of a piston ring as shown in fig. 1.12. These are made from fine-grained
alloy cast iron and machined carefully so that when in position, it is able to exert uniform pressure against the
cylinder walls.

A gap is cut at the ends to facilitate easy inserting into the piston ring grooves in the piston. The outer
diameter of the ring is somewhat larger than the cylinder bore and the split joint is open. The rings usually
have the but joints. N in some heavy duty engines, the joint may be angled, lapped or sealed type. Wher it is
installed, it is compressed thus gives an initial tension, the joint is nearly closel.

 Functions of Piston Rings:

The piston rings in 1 C. engine have to perform the following functions:

1. .To form a seal for the high pressure gases from the combustion chamber against leak into the
crankcase.

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2. To provide easy passage for the conduction of heat from the piston crown to the cylinder walls.
3. To control the flow of oil to the skirt and rings themselves in adequatequantity for lubrication.
4. To prevent excessive amount of lubricating oil reaching the combustion chamber with consequent
waste and carbonization.

 Following are the different types of pistons

1 Compression springs

2. Oil control springs

1. Compression Springs :

The compression rings perform the function of sealing the compression air-fuel mixture as it is compressed
and also the combustion pressure as the mixture horns. In modern engines, there are two or three
compression rings fitted into the top grooves. The number of compression rings tends to increase the
compression ratio The top compression ring has to do hard work of gas sealing and transfer heat from the
piston crown to the cylinder walls. Generally the second and third compression rings are taper-faced and
supplied to improve oil sealing. The compression rings also assist in controlling oil. The action of
compression rings when piston moves up and down as shown in fig. 1.1

2. Oil Control Rings:

The oil control rings perform the function of scrape off excessive oil from the cylinder wall and return it to
the oil pan., This is done to prevent the excessive amounts of oil from passing:

 between the ring face and the cylinder wall

 through the ring end gap and
 around behind the ring.

The oil control rings are fitted into the lower groove of the piston. In many cases these rings have a series of
slots which transfer excess oil through holes in the pinton grooves to the inside of the piston and so to the
sumps but leaves sufficient oil for lubricating the cylinder walls. The action of oil control ring when piston
is moving up and down.

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7. Connecting Rod:

The connecting rod is used to build the connection between the piston and the crankshaft.
Small end of the connecting rod is connected to the piston pin and big end to the crank pin as shown in fig.
1.15. The main function of the connecting rod is to convert the reciprocating motion of the piston into
throtary motion of the crank shaft.

Usually the connecting rod has 1-beam cross-section to provide maximum rigidity with minimum weight
and it is made up of forged steel: Aluminium alloy material is also used for making the connecting rod. They
are carefully matched in sets of uniform weight in order to maintain engine balance. The connecting rod
carries the power thrust from piston to the crank pin and hence it must be very strong, rigid and also as light
as possible..

8. Crankshaft and its Function:

Crankshaft is the engine component from which engine power is taken. It is the first part in the
power transmission system, it receives the power from connecting rods Le. reciprocating motion of the
piston is converted into the rotary motion. The rotary motion of the crankshaft is transmitted to the clutch

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and then to the wheels. The crankshaft consists of main journals, crankpins, crankwebs, balancing weights,
oil holes as shown in fig. 1.16 and 1.17.

Main journals are supported in main bearings in the crankcase, which becomes the axis of rotation of the
crankshaft. Big end of the connecting rod is connected to the crankpin of the crankshaft. Centre to centre
distance between the crankpin and crankshaft is half of the piston displacement during a stroke. Therefore,
one complete revolution of the crankshaft makes two strokes of the piston. Balancing weights are provided
on the opposite side of the crankarms for balancing.

 Camshaft and its Purpose:

camshaft is simply a shaft on which cams are mounted. The camshaft is mounted in bearings in
the lower part of the cylinder block in most of the in-line engines as shown in fig. 1.18. In some engines it is
located on the cylinder head. In V-8 engines, the camshaft is located between the two banks of cylinders

Engine Maintenance:

The engine maintenance is concerned to various engine troubles and repairs to maintain the engine perfectly
in working condition if the engine has no trouble, the automobile runs economically and without any
difficulty. Any trouble in the engine may stop the automobile Therefore, every trouble should be removed
Repair and servicing should be done time to time for the maintenance of the engine perfectly to keep in good
working condition.

Engine rebuilding is another method of engine servicing. Some companies setup special engine disassembly
and engine re-building lines. They bring in old engines, dissemble them completely, repair or replace all
worn parts and then completely re-build the engine. Before the engine is disassembled for service, it is
desirable to ascertain whether the overhauling is really necessary or not. Generally the overhauling is done
in the following situation:

1. Power loss due to poor engine compression may be due to the slipping of clutch, dragging brakes or
defective fuel system etc. In case power loss is not due to such factors, then the compression pressure may
be measured and comparing the value with those given in shop manual then, it may be decided whether the
engine requires overhauling or not.

2 Excessive consumption of lubricating oil.

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3. Lubricating oil pressure low, provided the same is not due to the external leakage, less oil in the
sump, defective oil pump or faulty oil pressure gauge.

4. Mechanical failures, such as excessive clearance in the main or big end bearings or in the valve
tappets, piston slap etc., may indicate that the overhauling is required. However, if excessive noise is due to
defective ignition or injection or faults in generator, water pump, etc.. the engine overhauling is not
necessary.

Dis-mounting of Engine (Procedure for Dis-mounting) :

Following procedure can be adopted for dis-mounting of engine

1.Before deciding whether it is necessary to remove the engine from the chassis, first it is essential to clean
the engine externally thoroughly so as to remove all surface grime. This makes it easier to inspect the engine
and to work on it and also helps to keep the dirt out of it while disassembling

2. While cleaning, take a special care not to damage electronic and fuel injection components. Cover any
part that can be damaged with a plastic bag.

3.Special attention should be given to any leakage, physical damage, external contamination etc.

4. If it is found to remove the engine, the engine have to be lifted removing the components that come in the
way of its removal and which are likely to damage while removing.

5. First of all the battery is removed and then the oil and coolant are drained off.

6. The hood of the engine compartment is then removed.

7. All coolant hoses are disconnected, the radiator mounting bolts are removed and the radiator is lifted from
the engine compartment.

8.If the engine is air conditioned, the compressor is disconnected from the engine and then it is removed

9. All air conditioning lines should be plugged to prevent the dirt and moisture going inside.

10. All wires, tubing and controls connecting the engine to the automobile are removed and tagged.

11. It is better that spark plugs, distributor, carburettor, alternator and fan are then removed to avoid the
damage to the engine.

12. After this the drive shaft and the exhaust pipes are disconnected. In some vehicles it is necessary to
remove the steering linkage also to make large space for the engine removal.

13. A hoist is then removed near the vehicle engine compartment and its sling connected to the manifold or
a lifting eye bolt on the engine top.

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14. The mounting bolts are then removed and the hoist is operated to lift the engine.

15. The engine is then swung clear and lowered into the engine stand on the blocks placed on the floor and
the hoist sling is disconnected.

Engine Disassembly (Procedural Steps to be followed for Disassembly of an

Engine) :
Following procedural steps can be adopted for disassembly of an engine:

1. Remove the cylinder head .

2. Take off all external accessories, like motor, dynamo ignition unit or injection pump.
3.Then remove the engine sump.

4.Take off timing gear cover, after removing pulleys etc.

5. Now, remove the clutch unit.

6. Take out all valves with their tappets, rocker arms, push rods, etc.
7 Then remove the connecting rod caps, pistons and connecting rods.

8. Take off timing chain and remove all sprockets.

9 Then remove the crankshaft with flywheel by taking off main bearing caps.

10. Now, remove the camshaft. 11. If necessary, drive out the valve guides.

12. Then disconnect the oil pump drive and remove the oil pump at the most convenient stage in the
proceeding operations. The oil filter and cleaner are also removed early on and also the disstick or oil
level gauge.

13. After removing all the components, they should be grouped conveniently on a bench or table, prior to
cleaning.

14. Before taking any component, make sure that it is marked identically with mating part

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Steps to be followed for Engine Re-assembly:

Following steps are generally followed for engine reassembly after servicing:

1. Make the final and thorough cleaning of all engine parts to remove any dust or dirt.

2 The crankshaft is thoroughly coated with the recommended lubricant and carefully placed.

3. The rear main oil seal is installed. The crankshaft and the new main bearings are lubricated.

4. The crankshaft is installed and bearing caps are fixed to the standard torque valves.
5.Timing gears, sprockets, chains, etc., are aligned and installed. The backlash in the timing gear or chain is
checked and ensured so that the same is within the limits. 6 7 The new oil seal is then installed in the timing
cover.

8 The timing cover is then installed using a new gasket. Before fixing the timing cover, the crankshaft
damper is also installed.

9.Piston connecting rod assemblies are installed.

10. Oil pump, cleaned and lubricated, is installed with new gasket and seals

11. The oil pan is installed with new gasket.

12. Cylinder head is assembled and installed. The valve filters and push rods are then placed, followed by
rocker arms, in correct locations. 13. Intake manifolds are fixed into the cylinder block, using new
gaskets

14. The water pump and outlet neck are then installed.

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15. In case the engine is to be fitted to automobile chassis directly, the other parts such as flywheel, clutch,
gear box housing, fuel pump, carburettor distributor, alternator, power accessories, fan belt, etc., are
installed.

THE REAL IMAGE OF HERO MOTOR :

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