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INDUSTRIAL TRAINING REPORT ON
KERALA AUTOMOBILES LIMITED,
THIRUVANANTHAPURAM, KERALA
TRAINING DONE FROM 14/05/2015 TO 20/05/2015
Submitted by
Akhil D
Sarath K.M
Hari Krishnan Thampi
Ayyappan R
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INDUSTRY PROFILE
The automobile industry in India has undergone drastic changes in terms of consumer perception
as well as technology since its inception. Automobile industry development provides necessary
infrastructure for economic development. Automobile industry in India has its beginning in
1950s; at that time generally carriage vehicles, tractors and other agricultural vehicles were
produced. In 1960s commercial vehicles available were very expensive and only the rich could
afford them. In between 1960-1970 manufacturing of commercial vehicles took shape.
Three wheeler industries in India had its beginning in early 1970s. The first three-wheeler
industry in India was API (Automobile Products of India) in 1971. But it was virtually
monopolized by Bajaj Auto Ltd., which was established in early 1970s.
KAL was incorporated in 1978 and was making losses in early years of its operations. Now
Kerala Automobiles became one of the profit making industries under the Government of Kerala
with a significant market share.
KAL is one of the major three-wheeler producers in India occupying about 10 acres of land.
Incorporated, as fully Government owned company on 15-3-1978 and production started in
February 1984. Initial technology was procured from Automobile Products of India (API)
Mumbai, but the collaboration terminated in 1987. Initially only petrol three wheelers were being
produced, but from 1988 onwards, KAL started producing diesel three-wheeler, which was1st of
its kind in India. At present, KAL produces five models of petrol three-wheelers and eight
models of diesel three-wheelers. KAL produces approximately 7200 vehicles per annum.
Recently KAL introduced three-wheeler tipper, exports to Sudan, Bangladesh, Sri Lanka,
Nigeria, Mexico, Iran, Nepal, etc.
Initially KAL was at loss, and hence it was registered with SIC Act, 1985 and Board of Industrial
Finance Re-construction (BIFR). In 1993-94, company, for the first time in the history, earned an
annual profit of 7.71 lakhs. Since then it has been registering profits every year.
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PLANT LAYOUT
The plant consists of an assembly unit, a fabrication unit, and workshop. The store room is
placed near to Inspection and testing unit. The layout resembles to a process layout, but it also
had the features of a line layout. But the machine in the plant placed according to the
convenience of the workers.
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PLANT DETAILS
MACHINE SHOP
The machine shop contains many machines for performing various operations. They include
semi automatic and fully automatic machines. Some of the machines include.
The bulk of operations for converting the metal parts into useful components to be used in three
wheelers are done at the machine shop. This section is the biggest section at KAL having the
largest share of qualified work force. This section ensures the quality standards at the
organization. The section has a large number of sophisticated machinery both automatic as well
as semiautomatic to produce the components at fast pace and satisfying stringent quality
standards. At each level of operation inspections are done to take appropriate action.
The raw materials used here at the machine shop includes those fabricated at the fabrication shop
and also castings and forgings imported from other factories. The machine shop also does jobs
for the space program of the VSSC.
CNC Lathes
CNC Milling Machines
Drilling Machines
Conventional Lathes Turret Lathe
Capstan Lathe Grinding Machine
Angular grinding Machine
Power Hacksaw
Tube bending machine etc
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CNC Milling Machines
CNC milling is a specific form of computer numerical controlled (CNC) machining.
Milling itself is a machining process similar to both drilling and cutting, and able to achieve
many of the operations performed by cutting and drilling machines. Like drilling, milling uses a
rotating cylindrical cutting tool. However, the cutter in a milling machine is able to move along
multiple axes, and can create a variety of shapes, slots and holes. In addition, the work-piece is
often moved across the milling tool in different directions, unlike the single axis motion of a
drill.
CNC milling devices are the most widely used type of CNC machine. Typically, they are
grouped by the number of axes on which they operate, which are labeled with various letters. X
and Y designate horizontal movement of the work-piece (forward-and-back and side-to-side on a
flat plane). Z represents vertical, or up-and-down, movement, while W represents diagonal
movement across a vertical plane. Most machines offer from 3 to 5 axes, providing performance
along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling centers, require
CAM programming for optimal performance due to the incredibly complex geometries involved
in the machining process. These devices are extremely useful because they are able to produce
shapes that would be nearly impossible using manual tooling methods. Most milling machines
also integrate a device for pumping cutting fluid to the cutting tool during machining.
Computer numeric controlled machining centers are used to produce a wide range of
components and tooling costs involved have continued to become more affordable. In general,
large production runs requiring relatively simple designs are better served by other methods,
although machining can now accommodate a wide range of manufacturing needs. CNC milling
centers are solutions to everything ranging from prototyping and short-run production of
complex parts to the fabrication of unique precision components.
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CNC Lathe
Computer numerical controlled (CNC) lathes are rapidly replacing the older production
lathes (multi spindle, etc.) due to their ease of setting, operation, repeatability and accuracy.
They are designed to use modern carbide tooling and fully use modern processes. The part may
be designed and the tool paths programmed by the CAD/CAM process or manually by the
programmer and the resulting file uploaded to the machine, and once set and trialled the machine
will continue to turn out parts under the occasional supervision of an operator.
The machine is controlled electronically via a computer menu style interface the program
may be modified and displayed at the machine, along with a simulated view of the process. The
operator needs a high level of skill to perform the process, however the knowledge base is
broader compared to the older production machines where intimate knowledge of each machine
was considered essential. These machines are often set and operated by the same person, where
the operator will supervise a small number of machines (cell).
The design of a CNC lathe varies with different manufacturers, but they all have some
common elements. The turret holds the tool holders and indexes them as needed, the spindle
holds the work piece and there are slides that let the turret move in multiple axis simultaneously.
The machines are often totally enclosed, due in large part to occupational health and safety
(OH&S) issues.
With rapid growth in this industry, different CNC lathe manufacturers use different user
interfaces which sometimes make it difficult for operators as they have to be acquainted with
them. With the advent of cheap computers, free operating systems such as Linux, and open
source CNC software, the entry price of CNC machines has plummete).
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These machines where used to a verity of operations. Some of them include
Facing
Drilling
Turing
Grinding
Threading etc.
Virtually every type of material that can be drilled or cut can be machined by a CNC mill,
although most of the work performed is done in metal. As with drilling and cutting, the proper
machine tools must be selected for each material in order to avert potential problems. The
hardness of the work-piece material, as well as the rotation of the cutting tool must all be
factored before beginning the machining process.
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Drilling Machines
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section
in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against
the work piece and rotated at rates from hundreds to thousands of revolutions per minute. This
forces the cutting edge against the work piece, cutting off chips (swart) from the hole as it is
drilled.
Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square
cross-section is possible.
Salient Features:
Massive and rigid construction
Ergonomically grouped controls for operating convenience.
Light centering of spindle
Precise depth release.
Electro-hydraulic clamping provided for drill head, arm & sleeve
Shock-free engagement of taps through clutch and spindle reverse for
withdrawals.
Machine with drilling capacity 80 mm / 100 mm also available
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Turret Lathe and capstan lathe
Turret lathes and capstan lathes are members of a class of lathes that are used for
repetitive production of duplicate parts (which by the nature of their cutting process are usually
interchangeable). It evolved from earlier lathes with the addition of the turret, which is an
indexable tool holder that allows multiple cutting operations to be performed, each with a
different cutting tool, in easy, rapid succession, with no need for the operator to perform setup
tasks in between (such as installing or uninstalling tools) nor to control the tool path. (The latter
is due to the tool-path being controlled by the machine, either in jig-like fashion [via the
mechanical limits placed on it by the turret's slide and stops] or via IT-directed servomechanisms
[on computer numerical controlled (CNC) lathes]).
There is a tremendous variety of turret lathe and capstan lathe designs, reflecting the variety of
work that they do.
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Conventional Lathes
A metal lathe or metalworking lathe is a large class of lathes designed for precisely machining
relatively hard materials. They were originally designed to machine metals; however, with the
advent of plastics and other materials, and with their inherent versatility, they are used in a wide
range of applications, and a broad range of materials. In machining jargon, where the larger
context is already understood, they are usually simply called lathes, or else referred to by more-
specific subtype names (tool-room lathe, turret lathe, etc.). These rigid machine tools remove
material from a rotating work piece via the (typically linear) movements of various cutting tools,
such as tool bits and drill bits.
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Surface grinder also includes wash grinder. A surface grinder has a "head" which is lowered to a
work piece which is moved back and forth under the grinding wheel on a table that typically has
a controllable permanent magnet for use with magnetic stock but can have a vacuum chuck or
other fixturing means. The most common surface grinders have a grinding wheel rotating on a
horizontal axis cutting around the circumference of the grinding wheel. Rotary surface grinders,
commonly known as "Blanchard" style grinders, have a grinding head which rotates the grinding
wheel on a vertical axis cutting on the end face of the grinding wheel, while a table rotates the
work piece in the opposite direction underneath. This type of machine removes large amounts of
material and grinds flat surfaces with noted spiral grind marks. It can also be used to make and
sharpen metal stamping die sets, flat shear blades, fixture bases or any flat and parallel surfaces.
Surface grinders can be manually operated or have CNC controls.
Tool and cutter grinder and D-bit grinder can usually perform the minor function of the drill bit
grinder, or other specialist tool room grinding operations.
Jig grinder, which as the name implies, has a variety of uses when finishing jigs, dies, and
fixtures. Its primary function is in the realm of grinding holes and pins. It can also be used for
complex surface grinding to finish work started on a mill.
Gear grinder is usually employed as the final machining process while manufacturing a high-
precision gear. The primary function of these machines is to remove the remaining few
thousandths of an inch of material left by other manufacturing methods (such as gashing or
hobbing).
Die grinder, which is a high-speed hand-held rotary tool with a small diameter grinding bit. They
are typically air driven (using compressed air), but can be driven with a small electric motor
directly or via a flexible shaft.
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Grinding Machine
A grinding machine, often shortened to grinder, is any of various power tools or machine tools
used for grinding, which is a type off-machining using an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's surface cuts a small chip from the work-piece via shear
deformation.
Grinding is used to finish work-pieces that must show high surface quality (e.g., low surface
roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in
grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation
and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some
roughing applications in which grinding removes high volumes of metal quite rapidly. Thus,
grinding is a diverse field.
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TYPES
Belt grinder, which is usually used as a machining method to process metals and other
materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is
the common name for machining metals. Belt grinding is a versatile process suitable for
all kind of applications like finishing, deburring, and stock removal.
Bench grinder, which usually has two wheels of different grain sizes for roughing and
finishing operations and is secured to a workbench or floor stand. Its uses include shaping
tool bits or various tools that need to be made or repaired. Bench grinders are manually
operated.
Cylindrical grinder, which includes both the types that use centers and the center-less
types. A cylindrical grinder may have multiple grinding wheels. The work piece is
rotated and fed past the wheel(s) to form a cylinder. It is used to make precision rods,
tubes, bearing races, bushings, and many other parts.
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Vertical machining centre
Salient Features:
Bed type machine configuration
Preloaded linear re-circulating guide-way system
AC Spindle motor
AC Servomotors for feed drive of all axes.
Automatic cyclic lubrication system for ball-screws and guide-way system.
Chip collection arrangement with chip conveyor.
Guide-way protection through telescopic covers/bellow covers.
Machine work lighting.
Cam driven high speed armless auto tool changer.
External coolant
Head counter balance
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Power Hacksaw
A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its
own electric motor or connected to a stationary engine. Most power hacksaws are stationary
machines but some portable models do exist; the latter (with frames) have been displaced to
some extent by reciprocating saws such as the Sawzall, which accept blades with hacksaw teeth.
Stationary models usually have a mechanism to lift up the saw blade on the return stroke and
some have a coolant pump to prevent the saw blade from overheating.
Power hacksaws are not as commonly used in the metalworking industries as they once
were. Bandsaws and cold saws have mostly displaced them. While stationary electric hacksaws
are not very common, they are still produced. Power hacksaws of the type powered by stationary
engines and line shafts, like other line-shaft-powered machines, are now rare; museums and
antique-tool hobbyists still preserve a few of them.
Pipe and Tube bending machine
Tube bending is the umbrella term for metal forming processes used to permanently form pipes
or tubing. One has to differentiate between form-bound and freeform-bending procedures, as
well as between heat supported and cold forming procedures.
Form bound bending procedures like "press bending" or "rotary draw bending" is used to
form the work piece into the shape of a Straight tube stock can be formed using a bending
machine to create a variety of single or multiple bends and to shape the piece into the desired
form. This process can be used to form complex shapes out of different types of ductile metal
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tubing.) Freeform-bending processes, like three-roll-push bending, shape the work piece
kinematically, thus the bending contour is not dependent on the tool geometry.
Generally, round stock is what is used in tube bending. However, square and rectangular
tubes and pipes may also be bent to meet job specifications. Other factors involved in the tube
bending process is the wall thickness, tooling and lubricants needed by the pipe and tube bender
to best shape the material and it is also used in different ways e.g.( tube, pipe wires).
FABRICATION
Fabrication when used as an industrial term, applies to the building of machines, structures and
other equipment, by cutting, shaping and assembling components made from raw materials.
The plant also contains a fabrication department. All the fabrication works were
performed here. Fabricator's shops vary both in the size of the facility and weight of material that
they can handle. The sophistication of the available equipment will also vary. Increasingly,
where investment is available, operations are being automated and computer-controlled.
Fabricators facilities may range from a very small operation, through to a large factory
involving many departments responsible for material procurement, material allocation, drawing
office, planning, welding, quality control, stockyard, preparation, fabrication, treatment, storage
and dispatch. Fabrication may also involve a number of fabrication shops each resourced with
different cranes, welding and other equipment to suit different product ranges.
In addition to the shop floor for the main production areas, areas may be set aside for the
trial assembly of certain elements. The remainder of the fabricator's premises will usually include
design and drawing offices, a template shop, and planning, administrative and estimating
departments.
Materials can be ordered direct from the producer where significant quantities of steel
are required; smaller quantities of a limited range of sections can be obtained from stakeholders.
Steel products are only sourced direct from the rolling mill if the quantity of a given size and
grade is sufficient. Otherwise they are sourced through steel stockholders who offer a wide range
of off-the-shelf profiles. As these are generally in standard lengths there may be some
additional cutting wastage, but a steelwork contractor may have a long-term partnering
arrangement with a stakeholders whereby: the stakeholders takes the risk of cutting wastage by
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delivering materials that are cut-to-length. The materials are delivered to the fabrication works
on a "just-in-time" basis to reduce the steelwork tractors need for working capital. The materials
may be pre-treated or pre-prepared in other ways (e.g.:- plates profiled and drilled).
Hydraulic Press
Presses are used in industrial settings for a wide variety of uses, including squeezing,
forming, and pressing. There are many different types of presses. Among the most popular these
days are pneumatic presses and hydraulic presses. These two models of presses are very similar
in function and can be used for a lot of the same things. However, there are some specific
differences between them to consider when attempting choosing between them. Hydraulic
presses are fundamentally chambers filled with some sort of liquid, usually oil. A piston presses
into the chamber, causing the oil to shift position. Since the chamber is sealed, the oil exerts
pressure on another, larger piston or base-plate, which is in turn pressed downwards.
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Pneumatic Presses
Pneumatic presses are controlled by the manipulation of pressurized air. The air is forced
into a tube which fills with the air and applies pressure that causes the press to move downwards.
Once the press' stroke is finished, the air is evacuated through valves, and mechanical springs
cause the pump to move upwards again.
Hydraulic presses and pneumatic presses can provide many of the same functions
with equal quality. They can both be adjusted to changed the stroke length or the
stroke pressure. They both have full tonnage and any position along their stroke,
making them preferable to mechanical presses. They can both perform
complicated pressing and forming tasks with the proper modification as you go
along.
The main difference between them is their speed. Pneumatic presses are much
faster than hydraulic presses, and that means there are many jobs they can
perform faster and more efficiently. However, this makes them ill-suited for
hydro-forming or other jobs where the hydraulic press' slower speed is an
advantage.
There are also differences as far as maintenance. Hydraulic presses require more
care, and have more components attached to them for this purpose, making them
more complicated. Pneumatic presses require less time and energy for
maintenance.
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WELDING
Welding is defined as a process where two or more pieces of metal or thermoplastics are fastened
together by use of heat and pressure. The process of applying heat softens the material and
enables it to affix together as one in a joint area when an adequate amount of pressure is applied.
The concept of welding first developed in the middle ages, though it did not form into the
process of welding as it is today until the latest years of the 19th century. Before this, a process
known as "forge welding" was the only means of joining two metal objects together. Forge
welding consisted of using a flame to heat metal to extremely high temperatures and then
hammering each piece together until they became one. This method was replaced around the
time of the industrial revolution. Electric and gas flame heating methods proved to be much safer
and faster for welders. Practically every material that has made society what it is today, was
created by welded construction tools or has been welded itself. Because of this, welders have a
wide range of areas for employment; many welders specialize in pipe welding or automobile
welding while others specialize in machinery. The possibilities are endless for welders seeing as
welding can be performed in a diverse range of locations, including underwater, though not all
forms of welding are the same. Some forms of welding use gas, while others use electric and the
newest forms involve use of a laser. The process of welding that is used depends on a variety of
factors but the form and thickness of the material is usually the deciding factor for which method
is most effective. Arc, Electro slag, Flux-Cored, Gas Metal-Arc, Gas Tungsten-Arc, Metal Inert
Gas, Plasma Arc, Shielded-Metal Arc, Submerged Arc and Tungsten Inert Gas are the most
widely used welding methods.
Arc welding machine
Arc welding is a popular form of welding due the low cost of the process. The process begins
with a device that gives off an electric current. This device can differ greatly from process to
process yet it always enables electric current to move through materials that without the
device, would be considered non-conductive. It is called 'arc welding' because an electrical
current is created between the welding device and the materials to be welded which at times
gives an arch like appearance. The first basic form of arc welding was invented in the year
1802. Today, many other subcategories of arc welding exist.
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Butt welding machine
Butt welding is a welding technique used to connect parts which are nearly parallel and don't
overlap. It can be used to run a processing machine continuously, as opposed to having to restart
such machine with a new supply of metals. Butt-welding Is an economical and reliable way of
joining without using additional components.
Usually, a butt-welding joint is made by gradually heating up the two weld ends with a weld
plate and then joining them under a specific pressure. This process is very suitable for
prefabrication and producing special fittings. Afterward, the material is usually ground down to a
smooth finish and either sent on its way to the processing machine, or sold as a completed
product.
This type of weld is usually accomplished with an arc or MIG welder. It can also be
accomplished by brazing. With arc welding, after the butt weld is complete, the weld itself needs
to be struck with a hammer forge to remove slag (a type of waste material) before any
subsequent welds can be applied. This is not necessary for MIG welds however, as a protective
gas removes any need for slag to appear. Another with a MIG welder is that a continuous copper
coated wire is fed onto the stock, making the weld virtually inexhaustible.
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Spot welding machine
Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in
the 0.5 to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped alloy
electrodes to concentrate welding current into a small "spot" and to simultaneously clamp the
sheets together. Forcing a large current through the spot will melt the metal and form the weld.
The attractive feature of spot welding is that a lot of energy can be delivered to the spot in a very
short time (approximately 10100 milliseconds). That permits the welding to occur without
excessive heating of the remainder of the sheet.
The amount of heat (energy) delivered to the spot is determined by the resistance between the
electrodes and the magnitude and duration of the current. The amount of energy is chosen to
match the sheet's material properties, its thickness, and type of electrodes. Applying too little
energy will not melt the metal or will make a poor weld. Applying too much energy will melt too
much metal, eject molten material, and make a hole rather than a weld another feature of spot
welding is that the energy delivered to the spot can be controlled to produce reliable welds.
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Metal Inert gas welding machine
Metal Inert Gas Welding is a process of welding that uses a gas to shield the weld metal. The gas
keeps the metal being welded from being effected from natural elements in the environment,
such as oxygen. This allows the welder to operate at a continuous rate, making the process fairly
quick. Operation of the equipment does not require an extreme level of skill by welders,
however, the equipment used in MIG Welding can only be used indoors due to the gas involved
in the welding process. MIG Welding was originally released in the 1940's but underwent many
upgrades until being perfected in the 1960's.
HEAT TREATMENT
Heat treatment is a critical and complex element in the manufacturing of gears that greatly
impacts how each will perform in transmitting power or carrying motion to other components in
an assembly. Heat treatments optimize the performance and extend the life of gears in service by
altering their chemical, metallurgical, and physical properties. These properties are determined
by considering the gear's geometry, power transmission requirements, stresses at different points
within a gear under load, load cycling rates, material type, mating part designs, and other
operating conditions. Heat treatments improve physical properties such as surface hardness,
which imparts wear resistance to prevent tooth and bearing surfaces from simply wearing out.
Heat treatments also improve a gear's fatigue life by generating subsurface compressive stresses
to prevent pitting and deformation from high contact stresses on gear teeth. These same
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compressive stresses prevent fatigue failures in gear roots from cyclic tooth bending. Physical
properties such as surface hardness, core hardness, case depth, ductility, strength, wear resistance
and compressive stress profiles can vary greatly depending on the type of heat treatment applied.
For any given type of heat treatment the results can be tailored by modifying process parameters
such as heating source, temperatures, cycle times, atmospheres, quench media, and tempering
cycles to meet specific application requirements.
IMPORTANT STEPS ARE
CARBURIZING
Carburizing is the most widely used form of surface hardening, is the process of diffusing carbon
into surface of low carbon steel at elevated temperatures. This results in a high carbon case
forming just inside the surface of a low carbon component. During quenching from austenitizing
the austenite will transform to martensite, and the higher carbon case will have a high hardness
while the lower carbon core material will have a lower hardness. The goal of this process is to
produce a hard, strong, wear resistant outer surface while retaining a softer, ductile tough core.
HARDENING
There are two general classifications of heat treatments used for hardening steels: neutral
hardening, and case hardening. Neutral hardening refers to maintaining the carbon potential of
the atmosphere at the same percentage as the carbon in the steel during the hardening cycle. This
means that carbon is entering and leaving the surface of the steel at the same rate, and no net gain
or net loss of carbon atoms inside the surface of the steel occurs. Many gears are neutral
hardened, but for the most demanding applications case hardening processes, such as carburizing
and nitriding, are the preferred methods due to their improved wear characteristics and
mechanical properties.
QUENCHING AND TEMPERING
Oriented toward carbide steels such as carbon-moly, this process is designed to enhance
toughness as well as controlling yield strength and ultimate tensile strength of steel. The steel is
heated to above its upper critical temperature and quickly immersed in fresh water or brine to
achieve rapid setting of the desired metallurgical structure. Oil quenching is sometimes used.
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The usual practice is to quench until cooling reaches around 8000F, quickly followed by a
tempering period in a fired furnace in order to soften the martensitic structure and achieve the
desired mechanical properties in the material including a desired measure of ductility. The
tempering process is, in effort, a stress relieving process.
ASSEMBLY SECTION
The Kerala Automobile has got separate assembly unit, where the assembly operations are
performed. This section mainly deals with the assembly of gearbox and gearbox-engine. The
engine is fitted to the chassis and them to the drive mechanism. After this the body is assembled
to the chassis. The electrification stage succeeds the above operations. The assembly operations
were aided by following machines, Hoists, universal Toll kits, fixtures, painting booths.
Wheels & Tyres
KAL vehicles use pressed steel disc wheels of divided type. The two halves are securely fastened
to form a rim having two fixed flanges. The tyre with tube is then fixed onto the wheel. KAL
uses MRF-savari brand of tyres for its vehicles.
Back plate Assembly
The drum brake system used consists of two brake shoes with friction material actuated by a
wheel cylinder. The parking brake is actuated by a cam. Retractor springs used for release of
brakes. Tension springs are placed beneath the brake shoes.
Differential Assembly
Matching planet and sun gears are selected and fixed on the seats provided in the differential
cage. Then the cross pin is inserted .the meshing of the gears are checked to see if there is any
backlash.
Propeller Shaft Assembly
The propeller shaft consists of two universal joints and sliding joint. Bevel pinion is attached to
one end via the universal joint .flexible ring type universal joint is used.
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Handle Bar Assembly
Handle bar consists of mechanisms for actuating clutch, accelerator and front brake it also
houses the switch assy. for light and other accessories.
QUALITY CONTROL
KAL uses computerized design system and testing equipment to ensure the international
standards. Quality assurance achieved through satisfied quality control methods has helped KAL
to achieved ISO 9001 Certification.
Verification inspection are done on each step of manufacturing and assembled to provide the
required specification and stranded. This has been made possible using equipments such as
Universal testing Machines, Dynamometers, Exhaust Analyzer, Digital Height Master, Eddy
Current Tester etc.
The QC system is designed to provide routine and consists checked to ensure data integrity,
correctness and completeness. QC activities includes general such as accuracy checks on data
acquisition and calculation and the use of approved standardized procedure for emission
activates Include a planned system of review procedures conducted by personal not directly
involved in the inventory development process.
CONCLUSION
The Industrial Training we had at KAL gave us an insight into the operation of an
automobile industry. We had a first-hand experience with the various departments in an
automobile industry, and also of the various operations done in those departments. We also came
to know the various challenges faced by an industry and how it overcame that adverse climate
through the strong determination of management and employees.
INDUSTRY PROFILE