Assembly of Gearbox no.

4028, 1613
A FIELD WORK REPORT

Submitted by

Name of student
In partial fulfilment for the award of the degree

Of

MASTER OF TECHNOLOGY
In
PRODUCTION ENGINEERING

BIKANER TECHNICAL UNIVERSITY

April, 2022
 CANDIDATE DECLARATION

I hereby declare that the work, which is being presented in the Field Project Report, entitled
“Assembly of gearbox no. 4028, 1613”in partial fulfilment for the award of degree of
“Master of Technology” in Dept. of Production Engineering with Specialization in
Mechanical Engineering, and submitted to the Department of Mechanical Engineering,
Modern Institute of Technology & Research Centre, Bikaner Technical University is a record
of my own investigations carried under the Guidance of Guide Name, Department of
Mechanical Engineering, College Name.
I have not submitted the matter presented in this report anywhere for the award of any other
Degree.

NAME OF STUDENT
Mechanical Engineering
College Name.
Counter Signed by,
Guide Name
Mechanical Engineering Department

i
 ACKNOWLEDGMENET

Field work is a crucial period in engineering curriculum since it exposes a student to the real
world which he or she is going to enter after the completion of the graduation. This is the
period during which an engineer actually becomes an engineer by gaining the Industrial
experience. I am very thankful to God who has given me the opportunity to get training in
TATA MOTORS one of the most renowned organization of India. I would like to express
my deep gratitude to my Project Head Mr. Yogesh Choudhary (Supervisor) for having
provided me with the wonderful & conductive environment to work in and realize what really
industry is he has been ever helpful and supportive. Last but not the least I would like to
thank Mr. Ravindra Singh (HR Manager) for providing me the opportunity to add a new
dimension to my personality. I will remain indebted to his for his generous ways of dealing
with industrial trainees.

NAME OF STUDENT
B. Tech (IV Year)
(Mechanical Engineering)

ii
 Abstract

Tata group is comprises over 100 operating companies in seven business sectors:
communication and information technology, engineering materials, services, energy,
consumer products and chemicals. The group has operations in more than 80 countries across
six continents, and its companies export products and services to 85 countries.

Tata motors limited is India’s largest automobile company, with consolidated revenues of
INR 10,65,654 crores in 2017-2018. It is the leader in commercial vehicles in each segment .
it is the world’s fourth largest truck and bus manufacturer .
Gearbox is the most important component of each and every vehicle. Without this we can’t
imagine a proper working of any vehicle because due to irregularity of roads and needs of
different speed and torque. Another important application of gear is to transmit power at a
minimum power loss.
Gear is a rotating machine part having cut teeth, or cogs, which mesh with another tooth part
in order to transmit torque. To or more gears working in tandem are called a transmission and
can produce a mechanical advantage through a gear ratio and thus may be considered a
simple machine.
There are two types of gear one is external another is internal ,both are widely used in
automobile industries for transmitting power at most effective ratio. Some major gear are :
spur gear, helical gear, bevel gear rack and pinion etc,
There are some victims of proper working of gearbox : it should not be noisy , there should
be correct alignment of gearbox clutch, not to loose gear spline. Not to slip gear in running
vehicle.
Proper working of gearbox result a good life to suspension system and engine working
because excuss force comes due to problem in gearbox which is very harmful for vehicle
performance.

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 CONTENT

Acknowledgement i
Declaration ii
Abstract iii

1 INTRODUCTION TO MATSYA AUTO LTD. ALWAR………………………………2

1.1 TATA JOURNEY………………………………………………………………………… 3
1.2 DIVISIONS………………………………………………………………………………......
1.21 Training division …………………………………………………………………….
1.22 Assembly division………………………………………………………………. … .
1.23 Maintenance division………………………………………………………………
1.3 TATA MOTORS ECONOMIC GRAPH………………………………………………….6
2 WHAT IS CROWN WHEEL:- ……………………………………………………………7
2.1 GEAR……………………………………………………………………………………….9
2.2 TYPES……………………………………………………………………………………..9
2.3 GEAR NOMENCLATURE……………………………………………………………….13
3 ENGINE……………………………………………………………………………………16
3.1 STROKES OF ENGINE…………………………………………………… ………….. 18
3.11 Intake stroke……………………………………………………………………………
3.12 Compression stroke…………………………………………………………………..
3.13 Power stroke……………………………………………………………………………
3.2 PARTS AND DESCRIPTION…………………………………………………………18
3.3 SPECIAL TOOLS FOR ENGINE……………………………………………………….19
4 SUSPENSION……………………………………………………………………………20
5 CLUTCH……………………………………………………………………………………21
215.1 TYPES……………………………………………………………………………………….
5.2 FUNCTIONS…………………………………………………………………………………
6 FAULTS IN SYSTEM………………………………………………………………………22
6.1 FAULTAS IN GEAR BOX………………………………………………………………
6.2 FAULTAS IN CLUTCH……………………………………………………………….…
6.3 FAULTAS IN BRAKING SYSTEM……………………………………………………..
6.4 FAULTAS IN ENGINE…………………………………………………………………..
6.5 FAULTAS OF PROPELLER SHAFT…………………………………………............
7 STEERING SYSTEM………………………………………………………………………25
7.1 MECHANISM………………………………………………………………………………
7.2 FUNCTION…………………………………………………………………………………
7.3 MAIN PARTS………………………………………………………………………………
7.4 TYPES ……………………………………………………………………………………..
8 STEERING GEOMETRY OF TATA VEHICLES…………………………………………..26
9 OVERVIEW……………………………………………………………………………………27
10 REFRENCES..........................................................................................................................30

1
 TATA MOTORS - Introduction

Tata Motors is a part of the Tata Group manages its share-holding through Tata Sons. The
company was established in 1935 as a locomotive manufacturing unit and later expanded its
operations to commercial vehicle sector in 1954 after forming a joint venture with Daimler-Benz
AG of Germany. Despite the success of its commercial vehicles, Tata realized his company had
to diversify and he began to look at other products. Based on consumer demand, he decided that
building a small car would be the most practical new venture. Soin 1998 it launched Tata Indica,
India's first fully indigenous passenger car. Designed to be inexpensive and simple to build and
maintain, the Indica became a hit in the Indian market. It was also exported to Europe, especially
the UK and Italy. In 2004 it acquired Tata Daewoo Commercial Vehicle, and in late 2005 it
acquired 21% of Aragonese Hispano Carrocera giving it controlling rights of the company. It has
formed a joint venture with Marcopolo of Brazil, and introduced low floor buses in the Indian
Market. Recently, it has acquired British Jaguar Land Rover (JLR), which includes the Daimler
and Lanchester brand names.

TATA JOURNEY –YEAR BY YEAR:-

2
➢ 1868: Jamsetji Nusserwanji Tata starts a private trading firm, laying the
foundation of the TATA group.

➢ 1874: The Central India Spinning, Weaving and Manufacturing Company is set
up, marking the Group's entry into textiles.

➢ 1902: The Indian Hotels Company is incorporated to set up the Taj Mahal Palace
and Tower, India's first luxury hotel, which opened in 1903.

➢ 1907: The Tata Iron and Steel Company (now Tata Steel) is established to set up
India's first iron and steel plant in Jamshedpur. The plant started production
in 1912.

➢ 1910: The first of the three Tata Electric Companies, The Tata Hydro-Electric
Power Supply Company, (now Tata Power) is set up.

➢ 1911: The Indian Institute of Science is established in Bangalore to serve as a

centre for advanced learning.

➢ 1912: Tata Steel introduces eight-hour working days, well before such a system
was implemented by law in much of the West.

➢ 1917: The Tata enter the consumer goods industry, with the Tata Oil Mills
Company being established to make soaps, detergents and cooking oils.

➢ 1932: Tata Airlines, a division of Tata Sons, is established, opening up the

aviation sector in India.

➢ 1939: Tata Chemicals, now the largest producer of soda ash in the country, is
established.

➢ 1945: Tata Engineering and Locomotive Company (renamed Tata Motors in 2003)
is established to manufacture locomotive and engineering products. Tata
Industries is created for the promotion and development of hi-tech industries.

➢ 1952: Jawaharlal Nehru, India's first Prime Minister, requests the Group to
manufacture cosmetics in India, leading to the setting up of Lakme.
manufacturing organization, Voltas, is established.

➢ 1962: Tata Finlay (now Tata Tea), one of the largest tea producers, is established.
Tata Exports is established. Today the company, renamed Tata
international, is one of the leading export houses in India.

➢ 1968: Tata Consultancy Services (TCS), India's first software services company,
is established as a division of Tata Sons.

➢ 1970: Tata McGraw-Hill Publishing Company is created to publish educational

and technical books. Tata Economic Consultancy Services is set up to
provide services in the field of industrial, marketing, statistical and techno-
economic research and consultancy.

➢ 2002: The Tata Group acquires a controlling stakein VSNL, India's leading
international telecommunications service provider Tata Consultancy Services

3
 (TCS) becomes the first Indian software company to cross one billion dollars
in revenues. Titan launches Edge, the slimmest watch in the world. Idea Cellular, the
cellular service born of a tie-up involving the Tata Group, the Birla Group and AT &
T, is launched. Tata Indicom, the umbrella brand for telecom services from the Tata
Tele services stable, starts operations.

➢ 2003: Tata Motors launches City Rover – Indicas fashioned for the European
market. The first batch of City Rovers rolled out from the Tata Motors stable in
Pune on September 16, 2003.

➢ 2004: Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South
Korea. TCS goes public in July 2004 in the largest private sector initial public
offering (IPO) in the Indian market, raising nearly $1.2 billion.

➢ 2005: Tata Steel acquires Singapore-based steel company NatSteel by

subscribing to 100 per cent equity of its subsidiary, NatSteel Asia.

➢ 2009: Tata Motors launched Tata Nano, world’s cheapest family car.

4
There are three divisions in TATA Motors, Alwar:

Training division:-

The Training Center at the Alwar plant aims at providing high quality Apprenticeship
Training. In addition, the Centre provides both internal and external training, support to
operators, supervisors and managers in areas like special skills and technology,
safety, personnel practices etc. The Alwar plant, after a major restructuring exercise, executed
a smooth transition from function based to process-based structure. By this structure, process
owners are required to meet stretched targets, and in order to do so, are required to encourage
individual learning and development of employees. A structured process is being followed to
establish and reinforce an environment that encourages innovation.

Assembly division:-

Alwar Plant started with the assembly of Medium Commercial Vehicles (MCVs) to meet the
demand in the Northern Indian market. However, in 1995, the unit started manufacturing bus
chassis of Light Commercial Vehicles (LCVs) and SUMOs. The facilities for manufacturing
the spare parts were set up and started supply of Crown wheel & pinion (CWP) in 1994.
Subsequently, G-16 & G-18 Gear Parts started in 1998. With the availability of G-16 gear
parts manufacturing facility, the Plant also started assembly of G-16 Gear Box to meet in-
house requirement for SUMO vehicles in the year 2000.Now TATA Motors Alwar has
started assembling of CNG MCV`s to meet the consumers demand. TATA Motors is also
producing Rear Engine
CV`s.

Mantainance Division:-

In TATA Motors Alwar Crown Wheel and Pinion are manufactured by various gear cutting
process. Machining (grinding and heat treatment) of Gear Box parts is also done here. These
gears are used in gearboxes or as spares. Now TATA Motors is assembling. Gear Box of
ACE (Newly launched small –CV) in Alwar itself. The Manufacturing unit of Tata Motors at
Alwar is the latest manufacturing facility of Tata motors and is located towards East of Alwar
plant.

TATA Motors economical graph:-

5
Tata Motors has filed a complaint before a Delhi court alleging infringement of its trademark
and copyright by unknown persons manufacturing and marketing spurious ancillary
automobile products under its name. In the complaint filed in the court of Chief Metropolitan
Magistrate Vidya Prakash , the company said it has learnt that some unknown persons were
engaging in business of manufacturing, trading, distributing, storing and selling counterfeit
and spurious...

WHAT IS A CROWN WHEEL

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A crown wheel is a type of circular gear wheel with teeth that extend perpendicular to the
base. While a traditional gear features teeth that sit parallel to the edges of the base, a crown
wheel's teeth sit on the surface of the wheel, forming a crown-like shape. Crown wheels are
considered a type of beveled gear, which is the general term for all gears with teeth located on
the surface of the wheel rather than the edges. The teeth on a beveled wheel may be placed at
any angle to the surface, while the crown wheel teeth are distinguished by the fact that they
are positioned at a 90-degree angle to the gear. These gears are often used along with a pinion
to rotate a mechanical device. They are used in many automotive applications, as well as in
industrial and manufacturing equipment. Many vehicles rely on crown wheel and pinion
systems to create the vehicle's forward motion, or to rotate the axles. A crown wheel gear is
also used with a pinion to operate a traditional mechanical clock. While standard gears line up
edge to edge, crown wheels mesh at an angle with pinions or other gears. Rather than being
located in the same plane, the two gears are positioned at an angle, or perpendicular to one
another. This allows the teeth in the gears to fit together and transfer motion or force between
various operating components.There are three basic types of crown wheel for buyers to
choose from. Standard models have squared-off teeth that sit parallel to the top of the gear.
This design results in a high level of vibration and noise when these gears are used. Spiral
gears use teeth with angled edges, resulting in quieter performance, but also in faster wear
and more maintenance. Hypoid crown wheels are similar to spiral models, but work with an
offset pinion to create better strength and performance. Users should select crown wheel
gears carefully to match the needs of the application. The size and pattern of the teeth on the
wheel must fit exactly with all adjacent gears or pinions. It is also helpful to choose higher
quality gears, because are more precisely made to minimize noise and vibration. The material
used to manufacture these gears is also a critical factor. If one gear is harder than the adjacent
one, it will rapidly wear away the edges of the softer gear, shortening the life of the
installation.

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When a car turns a corner, one wheel is on the "inside" of a turning arc, and the other wheel is
on the "outside." Consequently, the outside wheel has to turn faster than the inside one in
order to cover the greater distance in the same amount of time. Thus, because the two wheels
are not driven with the same speed, a differential is necessary. A car differential is placed
halfway between the driving wheels, on either the front, rear, or both axes (depending on
whether it’s a front-, rear-, or 4-wheel-drive car). In rear-wheel drive cars, the differential
converts rotational motion of the transmission shaft which lies parallel to the car’s motion to
rotational motion of the half-shafts (on the ends of which are the wheels), which lie
perpendicular to the car’s motion.

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 GEAR:

A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed
part in order to transmit torque. Two or more gears working in tandem are called a
transmission and can produce a mechanical advantage through a gear ratio and thus may be
considered a simple machine. Geared devices can change the speed, magnitude, and direction
of a power source. The most common situation is for a gear to mesh with another gear,
however a gear can also mesh a non-rotating toothed part, called a rack, thereby producing
translation instead of rotation. The gears in a transmission are analogous to the wheels in a
pulley. An advantage of gears is that the teeth of a gear prevent slipping. When two gears of
unequal number of teeth are combined a mechanical advantage is produced, with both the
rotational speeds and the torques of the two gears differing in a simple relationship.
In transmissions which offer multiple gear ratios, such as bicycles and cars, the term gear, as
in first gear, refers to a gear ratio rather than an actual physical gear. The term is used to
describe similar devices even when gear ratio is continuous rather than discrete, or when the
device does not actually contain any gears, as in a continuously variable transmission.

TYPES:-

1.External vs. internal gears

An external gear is one with the teeth formed on the outer surface of a cylinder or cone.
Conversely, an internal gear is one with the teeth formed on the inner surface of a cylinder or
cone. For bevel gears, an internal gear is one with the pitch angle exceeding 90 degrees.
Internal gears do not cause direction reversal.

2.Spur

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or
disk, and with the teeth projecting radially, and although they are not

9
straight-sided in form, the edge of each tooth thus is straight and aligned parallel to the axis of
rotation. These gears can be meshed together correctly only if they are fitted to parallel axles.

3. Helical

Helical gears offer a refinement over spur gears. The leading edges of the teeth are not
parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this angling
causes the tooth shape to be a segment of a helix. Helical gears can be meshed in a parallel or
crossed orientations. The former refers to when the shafts are parallel to each other; this is the
most common orientation. In the latter, the shafts are non-parallel.

The angled teeth engage more gradually than do spur gear teeth causing them to run more
smoothly and quietly. With parallel helical gears, each pair of teeth first make contact at a
single point at one side of the gear wheel; a moving curve of contact then grows gradually
across the tooth face to a maximum then recedes until the teeth break contact at a single point
on the opposite side. In spur gears teeth suddenly meet at a line contact across their entire
width causing stress and noise. Spur gears make a characteristic whine at high speeds and can
not take as much torque as helical gears. Whereas spur gears are used for low speed
applications and those situations where noise control is not a problem, the use of helical gears
is indicated when the application involves high speeds, large power transmission, or where
noise abatement is important. The speed is considered to be high when the pitch line velocity
exceeds 25 m/s.

4. Double helical

Double helical gears, or herringbone gear, overcome the problem of axial thrust presented by
"single" helical gears by having two sets of teeth that are set in a V shape. Each gear in a
double helical gear can be thought of as two standard mirror image helical gears stacked. This
cancels out the thrust since each half of the gear thrusts in the opposite direction. Double
helical gears are more difficult to manufacture due to their more complicated shape.For each
possible direction of rotation, there are two possible arrangements of two oppositely-oriented
10
helical gears or gear faces. In one possible orientation,the helical gear faces are oriented so
that the axial force generated by each is in the axial direction away from the center of the
gear; this arrangement is unstable. In the second possible orientation, which is stable, the
helical gear faces are oriented so that each axial force is toward the mid-line of the gear. In
both arrangements, when the gears are aligned correctly, the total (or net) axial force on each
gear is zero. If thegears become misaligned in the axial direction, the unstable arrangement
generates a net force for disassembly of the gear train, while the stable arrangement generates
a net corrective force. If the direction of rotation is reversed, the direction of the axial thrusts
is reversed, a stable configuration becomes unstable, and vice versa.Stable double helical
gears can be directly interchanged with spur gears without any need for different bearings.

5. Bevel

A bevel gear is shaped like a right circular cone with most of its tip cut off. When two bevel
gears mesh their imaginary vertices must occupy the same point. Their shaft axes also
intersect at this point, forming an arbitrary non-straight angle between the shafts. The angle
between the shafts can be anything except zero or 180 degrees. Bevel gears with equal
numbers of teeth and shaft axes at 90 degrees are called miter gears. The teeth of a bevel gear
may be straight-cut as with spur gears, or they may be cut in a variety of other shapes. Spiral
bevel gear teeth are curved along the
tooth's length and set at an angle, analogously to the way helical gear teeth are set at an angle
compared to spur gear teeth. Zero bevel gears have teeth which are
curved along their length, but not angled. Spiral bevel gears have the same advantages and
disadvantages relative to their straight-cut cousins as helical gears do to spur gears. Straight
bevel gears are generally used only at speeds below 5 m/s (1000 ft/min), or, for small gears,
1000 r.p.m.

6. Hypoid

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Hypoid gears resemble spiral bevel gears except the shaft axes do not intersect. The pitch
surfaces appear conical but, to compensate for the offset shaft, are in fact hyperboloids of
revolution.Hypoid gears are almost always designed to operate with shafts at 90degrees.
Depending on which side the shaft is offset to,relative to the angling of the teeth, contact
betweenhypoid gear teeth may be even smoother and moregradual than with spiral bevel gear
teeth. Also, the pinion can be designed with fewer teeth than a spiral bevel pinion, with the
result that gear ratios of 60:1 and higher are feasible using a single set of hypoid gears.This
style of gear is most commonly found in mechanical differentials.

9.Worm :

Worm gears resemble screws. A worm gear is usually meshed with an ordinary looking, disk-
shaped gear, which is called the gear, wheel, or worm wheel.Worm-and-gear sets are a simple
and compact way to achieve a high torque, low speed gear ratio. For example, helical gears
are normally limited to gear ratios of less than 10:1 while worm-and-gear sets vary from 10:1
to 500:1. A disadvantage is the potential for considerable sliding action, leading to low
efficiency.Worm gears can be considered a species of helical gear, but its helix angle is
usually somewhat large(close to 90 degrees) and its body is usually fairly long in the axial
direction; and it is these attributes which give it its screw like qualities. The distinction
between a worm and a helical gear is made when at least one tooth persists for a full rotation
around the helix. If this occurs, it is a 'worm'; if not, it is a 'helical gear'. A worm may have as
few as one tooth. If that tooth persists for several turns around the helix, the worm will
appear,superficially, to have more than one tooth, but what one in fact sees is the same tooth
reappearing at intervals along the length of the worm. The usual screw nomenclature applies:
a one-toothed worm is called single thread or single start; a worm with more than one tooth
is called multiple thread or multiple start. The helix angle of a worm is not usually specified.
Instead, the lead angle, which is equal to 90 degrees minus the helix angle, is given.In a
worm-and-gear set, the worm can always drive the gear. However, if the gear attempts to
drive the worm,itmay or may not succeed. Particularly if the lead angle is small, the gear's
teeth may simply lock against the worm's teeth, because the force component circumferential
to the worm is not sufficient to overcome friction. Worm-and-gear sets that do lock are called
self locking, which can be used to advantage, as for instance when it is desired to set the
position of a mechanism by turning the worm and then have the mechanism hold that
position. An example is the machine head found on some types of stringed instruments.If the
gear in a worm-and-gear set is an ordinary helical gear only a single point of contact will be

12
achieved. If medium to high power transmission is desired, the tooth shape of the gear is
modified to achieve more intimate contact by making both gears partially envelop each other.
This is done by making both concave and joining them at a saddle point; this is called a cone-
drive.Worm gears can be right or left-handed following thelong established practice for
screw threads.

10.Sun and planet:

Sun and planet gearing was a method of converting reciprocal motion into rotary motion
in steam engines.It played an important role in the Industrial evolution.The Sun is yellow, the
planet red, the reciprocating crank is blue, the flywheel is green and the driveshaft is grey

-:Gear Nomenclature:-

A right hand helical gear or right hand worm is one in which the teeth twist clockwise as they
recede from an observer looking along the axis. The designations, right hand and left hand,
are the same as in the long established practice for screw threads, both external and internal.

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Two external helical gears operating on parallel axes must be of opposite hand. An internal
helical gear and its pinion must be of the same hand.

Gear, wheel
The larger of two interacting gears.

Pinion
The smaller of two interacting gears.

Path of contact
Path followed by the point of contact between two meshing gear teeth.

Line of action, pressure line

Line along which the force between two meshing gear teeth is directed. It has the same
direction as the force vector. In general, the line of action changes from moment to moment
during the period of engagement of a pair of teeth. For involute gears, however, the tooth-to-
tooth force is always directed along the same line—that is, the line of action is constant. This
implies that for involute gears the path of contact is also a straight line, coincident with the
line of action—as is indeed the case.

Axis
Axis of revolution of the gear; center line of the shaft.

Pitch point, p
Point where the line of action crosses a line joining the two gear axes.

Pitch circle, pitch line

Circle centered on and perpendicular to the axis, and passing through the pitch point. A
predefined diametral position on the gear where the circular tooth thickness, pressure angle
and helix angles are defined.

Pitch diameter, d
A predefined diametral position on the gear where the circular tooth thickness, pressure angle
and helix angles are defined. The standard pitch diameter is a basic dimension and cannot be
measured,but is a location where other measurements are made. Its value is based on the
number of teeth, the normal module (or normal diametral pitch), and the helix angle. It is
calculated as:in metric units or in imperial units.

Module, m
A scaling factor used in metric gears with units in millimeters who's effect is to enlarge the
gear tooth size as the module increases and reduce the size as the module decreases. Module
14
can be defined in the normal (mn), the transverse (mt), or the axial planes (ma) depending on
the design approach employed and the type of gear being designed. Module is typically an
input value into the gear design and is seldom calculated.

Operating pitch diameters

Diameters determined from the number of teeth and the center distance at which gears
operate.Example for pinion:

Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial direction. More
generally, the surface formed by the sum of all the pitch circles as one moves along the axis.
For bevel gears it is a cone.

Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth first make
contact, the other leg on the point where they disengage.

Arc of action
Segment of a pitch circle subtended by the angle of action.

Pressure angle, θ
The complement of the angle between the direction that the teeth exert force on each
other,and the line joining the centers of the two gears.For involute gears, the teeth always
exert force along the line of action, which, for involute gears, is a straight line; and thus, for
involute gears, the pressure angle is constant.

Outside diameter, Do
Diameter of the gear, measured from the tops of the teeth.

Root diameter
Diameter of the gear, measured at the base of the tooth.

Addendum, a
Radial distance from the pitch surface to the outermost point of the tooth.
a = (Do − D) / 2

Dedendum, b
Radial distance from the depth of the tooth through to the pitch surface.
b = (D – root diameter) / 2

15
Backlash
Backlash is the error in motion that occurs when gears change direction. It exists because
there is always some gap between the trailing face of the driving tooth and the leading face of
the tooth behind it on the driven gear, and that gap must be closed before force can be
transferred in the new direction. The term "backlash" can also be used to refer to the size of
the gap, not just the phenomenon it causes; thus, one could speak of a pair of gears as having,
for example, "0.1 mm of backlash." A pair of gears could be designed to have zero backlash,
but this would presuppose perfection in manufacturing, uniform thermal expansion
characteristics throughout the system, and no lubricant. Therefore, gear pairs are designed to
have some backlash. It is usually provided by reducing the tooth thickness of each gear by
half the desired gap distance. In the case of a large gear and a small pinion, however, the
backlash is usually taken entirely off the gear and the pinion is given full sized teeth.
Backlash can also be provided by moving the gears far

ENGINE

The names of the various parts of a reciprocating engine necessary for an undertaking of the
subject matter are following. The cylinder is the cylindrically shaped container with in which
the piston travels in position in the cylinder block,attached to,or an integral part of
crankcase.The vol. enclosed by the upper part of the cylinder and the top of the piston during
combustion process is called the combustion chamber.
In the spark ignition engine amixture of
fuel and air from the carburettor enters in the cylinder through intake manifold and intake
part. A throttle in the carburettor controls the mass of mixture entering the combustion
chamber.An intake valve is located at the junction of intake prt and cylinder. A spark
plug ,located near the top of the cylinder,initiates combustion.The piston and piston rings
prevent the escape of the expanding gases from the combustion chamber energy of the
expanding gases is through an intake part located in the side of cylinder.No carburator or
throttle is therefore necessary.Also since combustion the cylinder,no spark plug is needed.

16
How engine works?

Intake Valve

TERMONOLOGY OF ENGINE:

1) BORE: The inside dia. of the cylinder is called the bore and measured in inches.
2) STROKE:The linear distance during the travel of the piston measured parallel to the
axis of the cylinder.Between the extreme upper and lower positions of piston is
termed the stroke and is measured in Inches
3) TOP DEAD CENTER: The position of the piston when during its linear
travel,it is closest to the top of cylinder.
4) BOTTOM DEAD CENTER: The position of the piston farthest from the
top of cylinder is called BDC.
5) CLEARANCE VOLUME:The volume contained in the cylinder above the
top of piston when the piston is at TDC is called the clearance volume (m3).
6) COMPRESSION RATIO: The ratio of the volume when the piston is at
BDC to the volume when the pisyon is at TDC called the C.R

STROKES OF THE ENGINE :-

1) INTAKE STROKE:- Intake valve open exhaust valve closed piston moving
down brings in fresh combustile mixture of fuel and air from carburator.
2) COMPRESSION:-Both valve closed combustible charge is compressed by
the upward moving piston.

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 3) POWER STROKE:-Both valves closed compreesed combustible charge is
ignited by the spark plug and expanding gassed forced piston down.
4)EXHAUST STROKE:-Exhaust valve open intake valve closed products of
combustion forced out through the exahaust valve by the upward moving piston.here
is one complete cycle gives one power stroke.

ENGINE:PARTS AND DESCRIPTION:-

 CYLINDER HEAD:-It is made of cast iron .the head has a combustion chamber
and also place for spark plug or injecter.
 PISTON:-Piston is the main part of engine.piston reached,the power developed in
the power stroke to the crank shaft by the connecting rod.
 GUDGEON PIN:-It is also called piston pin and it connects the small end of
connecting and of connecting with piston.
 CYLINDER:-It is a hollow tube in the cylinder block .In this piston move in
reciprocating motion.
 CYLINDER LINEARS:-It is a centrifugal casting by a special method so that any
blow hole never
 OIL PUMP:-Oil pump is made by pressing the steel sheet.It is the lowest part of
engine.Oil is always filled in this.
 CRANK SHAFT:-Crank shaft changes the pistons upper down motion to the rotary
motion.
 FLY WHEEL:-Fly wheel is a round wheel of steel casting.It is absorbed the extra
energy and released it to necessary of energy it provides the jacks.
 CONNECTING ROD:-It connects the piston to the crank shaft by the gudgeon
pin.so that piston developing power reached to the crank shaft.

SPECIAL TOOLS FOR ENGINE

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  Drift for removal of exhaust valve guides and installation.
 Go-No –Go Gauge for exahaust valve guide.
 Guide wish for rearing exhaust valve guide.
 Reamer for new inlet valve guides 9mm dia.
 Puller for generator pulley .
 Tool for installing 7th main bearing oil seal.
 Angle Indexing Tool.
 Sleve C to be used with no eighteen.
 Spanner For turning crank shaft.
 Adaptor for checking engine compression.
 Rinch or Rey no.6-7 to no. 30-32
 Goties no. 10 to 36
 Hammer medium size
 Drive screw 12 inches,6,1.5 inches
 Toppet gauge-1
 L end key spanner no.5 & 6
 Screw driver small,medium,large

SUSPENSION:-

 Front-independent lower wise bone me pheason start type.

 Rear-independent semi trailling arm with coil spring mounted on hydraulic
shock absorber.
 Streering-manual racks pinion racks & pinion steering gear with steering
cilumn.
 Brake-deal ckt. diagonal split hydraulic brake tandom master cylinder through
the tyre.
 Fuel Filter-twin bowl engg. oil capacity 4 litre.

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 Suspension System

 Supports the weight.

 Provides a smooth ride.
 Allows rapid cornering without extreme body roll.
 Keeps tires in firm contact with the road
 Prevents excessive body squat
 Allows front wheels to turn side-to-side for steering
 Works with the steering system to keep the wheels in correct alignment

Basic Parts of Suspension system

Control arm – movable lever that fastens the steering knuckle to the vehicle’s body or
frame.
Steering Knuckle – provides a spindle or bearing support for the wheel hub, bearings and
wheel assembly.
Ball Joints – swivel joints that allow control arm and steering knuckle to move up and down
and side to side

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Springs – supports the weight of the vehicle; permits the control arm and Wheel to move up
and down
Shock absorbers or dampeners – keeps the suspension from continuing to bounce after
spring compression and extension
Control arm bushing – sleeves that allows the control arm to swing up and down on the
frame.

Non-independent suspension:- Has both right and left wheel attached to the same solid
axle. When one wheel hits a bump in the road, its upward movement causes a slight tilt of the
other wheel

Independent suspension:- Allows one wheel to move up and down with minimal effect
to the other.

SHOCK ABSORBER

 Limits spring compression extension movements to smooth the vehicle’s ride.

 Without shock absorbers, the vehicle would continue to bounce up and down
long after striking dip or hump in the road.

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FUNCTION

1. Cush drive
2. Absorb the road shocks
3. Put the body level straighter
4. Suspension system is reached driving torque to the wheels.

-:CLUTCH:-

clutch is a mechanism for transmitting rotation, which can be engaged and disengaged.
Clutches are useful in devices that have two rotating shafts. In these devices, one shaft is
typically driven by a motor or pulley, and the other shaft drives another device. In a drill, for
instance, one shaft is driven by a motor, and the other drives a drill chuck. The clutch
connects the two shafts so that they can either be locked together and spin at the same speed
(engaged), or be decoupled and spin at different speeds (disengaged).

Types of clutches
a) Cone clutch
b) Single plate clutch
c) Multi plate clutch
d) Multiplate wet clutch
e) Semicentrifugal clutch

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 f) Centrifugal clutch

FUCNTIONS OF CLUTCH
i. To be brake the engines power to gear box.
ii. To dis engaging the power to brake down the vehicle.
iii. To change gear easily by disengage power b/w engine and gear box.

FAULTS IN SYSTEMS

FAULTS OF GEAR BOX

1) To be noise in the gearbox.

2) Do not correct alignment gear box clutch.
3) To be loose the gear spline.
4) To be slip the gear in running vehicle.
5) To be grind the gear
6) To be brake the fork.
7) To be weak The fork Rod spring.
8) To be leakage the gear oil.
9) To be loose the drain plug.

GENRAL FAULTS OF CLUTCH

1) To be clutch’s slip.
2) To be noise in clutch working.
3) To be clutch’s drag.

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 4) Clutch vibrate.

FAULTS IN BRAKING SYSTEM

1) Brake binding
2) Vehicle pulls in one side
3) Brake pedal spongy.
4) Noisy brakes.
5) Padel down.

FAULT IN ENGINE AND REMIDIES

DID NOT START THE SELF RESTARTER:-

a. Do not Diesel supply by the pump.
b. To be close the fuel cock open - it.
c. To be close fuel inlet pipe cleaning the pipe.
d. To be choke the fitter aliment change aliment.

TO BE CLOSED ON THE LOAD

a. Do not full diesel supply to the injecter.
b. To be enter the air in fuel system bleeding.
c. To be check fuel filter charge.

DID NOT GIVE FULL POWER BY ENGINE

a. To be enter air in engine system
b. To be choke fuel pipe line cleaning by air pressure
c. To be choke fuel filter

TO GIVE BLAE SMOKE BY THE ENGINE

a. To give block smoke by engine.
b. To be closed the inlet port clean
c. To be close air cleaner.

FAULTS OF PROPELLER SHAFT

A. Shaking the propeller shaft.

B. Do not correct fitting the spline yokes.
C. To be bend the propeller shaft.
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 D. To be noise the propeller at running time.

STEERING SYSTEM:-

Steering mechanism:-Device by which driver moves the vehicle left or right.

Function:-
 Steering should be soft and easy in turning.
 It’s structure should be that it never fail.
 it structure should be that shocks .

Main parts of steering:-

a. Steering wheel b.Steering droparm

c. Steering outer tube d. Steering gear box
e. steering shaft

Types:
i. Worm and sector
ii. Worm and roller
iii. Worm and nut
iv. Worm and nut with reciprocating ball type
v. Cam and lever type
vi. Rack and pinion type
vii. Worm and wheel type

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 Steering geometry in different tata vehicles:

New model of Sumo:-

Caster - 2.5-3.5 degree
Camber - 20–40 degree
Toe in - 1.60-2.30 mm

TATA Seaira:-
Caster -3.50-4.50 Minitel hour
Caster – 20-40 Between minute
Toe in - 3.5 mm

TATA indica:-
Camber- 20-40 degree
Toe in- 40-60 mm

Wheel alignment:-
The centering of the wheel and not wear.Main case of failure of the wheel
alignment.
1. Ball joint brake down
2. Bearing brake down

Solution:-
1. Balancing of caster
2. Camber adjustment
3. Toe in adjustment in indica

TATA sumo:-
Caster- 20-40 degree
Camber- 20 degree
Toe in – 1-5 mm

Overview :-

 RESEARCH ON TATA MOTORS

 Industry ->Automotive Founded - 1945Founder(s)- JRD Tata

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 HEAD PERSONS Chairman – Mr. Sirus mistri Vice Chairman - Ravi kant

 CEO – Carl Peter Foster

 Prakash Telang - MD (India Operations)Ravi Pisharody- President (CVBU)

 Products Services Automobiles Engines Outsourced Engineering Design

 RECORDSRevenue$14.250 billion (2010)Operating income$10.40 billion (2010)Net

income$1.198 billion (2010)Total assets$15.430 billion (2010)Total equity$763 million
(2010)

 Subsidiaries Jaguar Land Rover TDCV Hispano Carrocera

 TATA TAKES OVER Jaguar and Land Rover brands Daewoo

 Tata Motors Limited acquired Daewoo Motor's Commercial vehicle business in 2004 for
around USD $16 million.

 Strength The benefit is that Tata has been able to exchange expertise. For example after the
Daewoo acquisition the Indian company leaned work discipline and how to get final product
rights first time. Company has successful alliance with Italian producer fiat since 2006. This
has exchange the product profile of Tata. Style was launch by Tata in 2007 and the company
have agreement to built our pick targeted at central and south America.

 Weaknesses The company's passenger car products are based upon 3rd and 4th generation
platforms, which put Tata Motors Limited at a disadvantage with competing car
manufacturers. Despite buying the Jaguar and Land Rover brands Tata has not got a foothold
in the luxury car segment in its domestic, Indian market.

 One weakness which is often not recognised is that in English the word 'tat' means rubbish.
Would the brand sensitive.  British consumer ever buys into such a brand? Maybe not, but
they would buy into Fiat, Jaguar and Land Rover.

 Opportunities The new global track platform is about to be launched from its Korean
(previously Daewoo) plant.In the summer of 2008 Tata Motor's announced that it had
successfully purchased the Land Rover and Jaguar brands from Ford Motors for UK £2.3
million.

 Threats Other competing car manufacturers have been in the passenger car business for 40,
50 or more years. Therefore Tata Motors Limited has to catch up in terms of quality and lean
production. Since the company has focused upon the commercial and small vehicle segments,

27
 it has left itself open to competition from overseas companies for the emerging Indian luxury
segments

 Tata Novus Tata Novus is one of the bestselling commercial trucks in South Korea

 Hispano CarroceraIn 2005, sensing an opportunity in the fully-built bus segment, Tata
Motors acquired a 21% stake in Hispano CarroceraSA.

 The leading European bus and coach cabin maker. In 2009, the company picked up the
remaining 79% stake in Hispano Carrocera SA for an undisclosed sum, making it a fully-
owned subsidiary.

 Tata Xenon is Tata's bestselling vehicle in Europe.

 Financial Highlights The company's strong operating cash flows helped the company to
bring down its interest cost in Financial Year 2004.The company had a negative working
capital in Financial Year 2004., the second year in running.

 Outlook The Company expects to outperform the industry in FY05. This is based on an
expected GDP growth rate of 6-6.5% .The Company is currently among the top five players
in the global MHCV segment, which includes players like FAW, Volvo etc.

VARIOUS ENGINE SPECIFICTION:

Engine No. ES-222 ES-322 ES-321 ES-422 ES-421 ES-461 ES-621

No. of Cylinders 1 2 2 3 3 3 3

Power (In Hp) 22 24 32 38 45 52 61

Diesel Tank(Lt) 30 45 45 45 45 45 45

Fuel Consumption
175 164 164 160 160 - -
In (gm/bhp/hr)

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 Lubricant
Less than Less than
Consumption In 1.5 .5 .5 - -
0.5 0.5
(gm/bhp/hr)

Cooling Air Air Air Air Air Water Water

Handle/
Starting Self Self Self Self Self Self
Self

REFRRANCES
 Guidance of my project head and the working staff.
 TATA MOTORS catalogue
 V B BHANDARI
 www.tatamotots.in
 www.wikipedia.com

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