PUNJABI UNIVERSITY

(DEPARTMENT OF MECHANICAL
ENGINEERING)
PATIALA

PROJECT - SUMMER TRAINING

(June-July, 2014)

ANMOL ASDHIR
11203172

TRAINING RENDERED
AT

Plot no. 2, Industrial

Phase IX,
S.A.S. Nagar (Mohali),
Punjab - 160062.

SELS PROFILE
SWARAJ ENGINE DIVISION
This plant is located in Mohali. It was setup in technical
and financial collaboration with KIRLOSKAROIL ENGINE
LIMITED. It was setup in the year 1987 for the
manufacture of diesel engines. This plant
manufactures engines for SWARAJ TRACTORS. It also
supplies connecting rods to SWARAJ MAZDA DIVISION.

DEPARTMENTS IN INDUSTRY
1. RESEACH AND DEVELOPMENT

2.INDUSTRIAL ENGINEERING

3.FINANCE DEPARTMENT

4.PRODUCTION DEPARTMENT

5. HUMAN RESOURCE

6.ASSEMBLY DEPARTMENT

ENGINE PARTS MANUFACTURED

IN SWARAJ ENGINE LIMITED
Various operations are performed on all the engine parts in

industry. I have tried to cover each and every part as per it was
possible as told by my training teacher MR. SHASHANK
AGGARWAL in SEL.
Various parts are as follows1. CONNECTING ROD
2. CYLINDER BLOCK
3. CYLINDER HEAD
4. CRANK CASE
Finally, after this the parts are sent to assembly department for

assembling them in proper engine

1.CONNECTING ROD
OPERATIONS PERFORMED ARE AS

FOLLOWS-

1. BOLT HOLE OPERATION

First of all number is punched on to both the cap and
rod like CTG where C stands for Con Rod ,T-Tractor
part ,G-Monthly code.
The next operation is to drill out holes in both the cap
and rod.
The next step is chamfering on rod
The next step is rough assembly of conrod

2. SEMI FINISH BORE

Rough boring is carried out on both the small and large
end of the conrod.

The next step is chamfering of the large end

After thus the bush is pressed in the conrod
The next step is drilling of oil hole

 Finally the machining of big end and of bush in small end is

carried out
The last step is most important one in which the weight
groups are assigned to the conrod according to standard
weight chart that is mentioned in the industry

2. CYLINDER BLOCK
Various steps in manufacturing of block are
1. MILLING

First of all face milling of rough piece is carried out

2. VMC(VERTICAL MILLING CUTTING)
Rough boring is carried out so that the boring of 4 holes
is carried out
3. HMC(HORIZONTL MILLING CUTTING)
This is the final setup in which the horizontally the
block is drilled hole that is the water face.

Finally the washing is carried out in which the

LEAK TESTING MACHINE
NUMBERING
CORE PLUG
In leak test there are two test 1.WATER WAYS

LEAK TEST 2. OIL WAYS LEAK TEST.

3. CYLINDER HEAD

1. The very first step in manufacturing of the

cylinder head is WASHING, PUNCHING

2. The next and important step is setting up of inlet
and outlet chamfer.
3. The next step is DEPTH MEASURE
4. The next step is
PLUGGING
HEAD LEAK TEST ASSEMBLY 1.STEM ASSEMBLY
2. SPRING ASSEMBLY

 6. The next step is TAPPING and CHAMFERING carried

on same machine with auto lever feed

7.On the top side LINER BORE , STEPPED BORE, STUDD
BORE
8. The next step is Gallery Operations carried on crank
case.The various steps in this step are WASHING- whole of the gallery is washed properly
PUNCHING
OIL GALLERY MATCHING OPERATION
REAMING TAPPING

9. The ASSEMBLY OPERATION is the next step carried out

STUD 16*2
CAP ON THE GEAR SIDE, TAPPING CAP, PLANE CAP, FLYWHEEL

CAP
TOLERANCE 18 KG
10.Then finally PUNCHING and SEMI-FINISH BORE
11. Then DUPLEX FINISH CUT MILLING is carried on both sides
that is flywheel and gear side
12. Then DOWEL BORING that is enlargement of the cam bore
is carried out
13. Finally washing is there .The LEAK TEST GALLERY TEST is
carried on that is same the air ways test and oil ways test.

ASSEMBLY
Various stages of assembly department are there 1. 1ST STAGE
Flywheel side hole is closed with the help of Impact

wrench.
CAMSHAFT-First of all gear to be fitted is heated at
high temperature so that it fits properly. It is a type of
CLEARENCE FIT, after cooling it expands and fits
properly in the cam shaft.

 CRANK SHAFT (A crank shaft related to the crank is a

mechanical part able to perform a conversion between

a reciprocating and rotational motion. )
. All these parts including cam shaft, lubrication oil
pump, caps are fitted on the crank case.
After this oil seal housing is fitted and assembly is sent
further for more attachments.

 2. 2ND STAGE
There is proper gear matching between intermediate

gear, cam gear inner and crank shaft gear.

Then after this, studs are tightened and gear case
(gasket stud, pointer, nut and bolts). Next step
mounting GEAR CASE on the crank case along with it
oil filter is also mounted on the crank case.
The next step is GEAR CASING OIL SEEL is mounted

 PISTON CYLINDER ARRANGEMENT

First of all, guzen pin is mounted on the piston head

and then the connecting rod is mounted on the piston.

The piston is then inserted in the cylinder head to
complete the assembly. On the piston, total 3 rings are
mounted. The upper 2 are oil rings and the 3rd is
compress ring.
The piston cylinder arrangement is then inserted in the
crank case on the crank shaft.
.

 3. 3RD STAGE
The next and the important step is BUMPING

CHECKING( Bumping is done to check that the cylinder

doesnt touch the valves at all and while the fuel
injection and fuel burning program in engine).
The next step is mounting DELIVERY BODY, SUCTION
TUBE, PUSH ROD, EXHAUST MANIFOLD, WATER
OUTLET is mounted on the cylinder head.

 4TH STAGE
In this,the ROCKER ARM ASSEMBLY is first mounted
above the three cylinders. Then the FUEL INJECTION
PUMP is mounted on. Along with it OIL COOLER PIPE is
also mounted on.
The important thing is checking the FUEL TIMING is set
(In this the fuel is set up that is how much fuel should
be delivered to meet the power requirement and fuel
must be injected at proper time)
Finally oil sump, fuel filter, water separator is

mounted on and cooling plate is mounted on

 The engine is near to completion it is further sent for

FLYWHEEL(Aflywheelis a rotating mechanical

device that is used to storerotational energy.
Flywheels have a significantmoment of inertiaand
thus resist changes in rotational speed. Energy is
transferred to a flywheel by applyingtorqueto it,
thereby increasing its rotational speed.) to be mounted
on it.