SUMMER TRAINING PROJECT

REPORT

INDIA YAMAHA MOTOR PVT. LTD.

SUBMITTED BY:-
PRABHAT TIWARI
B.TECH
MECHANICAL DEPARTMENT

SESSION: 2012-2016

DIT, AMITY GROUP OF INSTITUTION

 PREFACE

As a part of course curriculum of Bachelor of Technology we were asked to

undergo 4 to 6 weeks summer training in any organization so as to give us
exposure to practical skill and competence to get us familiar with various
activities taking place in the organization.

Our institute also believe in close and continuous Industrial Academy

interaction in order to enhance the capability of student to imbibe rich and
practical exposure useful for the corporate world.

I have put my sincere efforts to accomplish my objectives within the stipulated

time. I have worked to my optimum potential to achieve desired goals. I came
across some difficulties to make my objective a reality. With the kind help and
genuine interest and the guidance of my supervisor, I tried my level best
to conduct a research to gain a thorough knowledge about the project. I put
the best of my efforts to bring out this piece of work; if anywhere, something is
found unacceptable or unnecessary to the theme valuable suggestions are
thankfully acknowledged

Thanks and Regards

Yours sincerely
KHUSHBOO PANDEY
 ACKOWLEDGEMENT

I would like to express my gratitude to all the people who provided me with
support and guidance throughout the course of my summer internship
program
Firstly I would like to thank Mr. Bhavesh Kumar (HR department), Vijay Khanna
(HR department) and Shaima Tayyab (HR department) for giving me an
opportunity to undergo summer training at SHRI GANESHAM YAMAHA MOTORS
PVT LTD, Deeg Road , bharatpur. I am deeply indebted to Mr. S.K Gulati and Mr.
Rajendra Kumar (Crankshaft department) without the supervision and
continued guidance of whom it wouldn’t have been possible to complete this
project.
I would also like to thank Mr. A.K Sharma for providing me this wonderful
opportunity to work with the YAMAHA family.

Thank you
KHUSHBOO PANDEY
 CONTENTS

1. Preface
2. Acknowledgement
3. Content
4. Overview
5. About Yamaha Motors
History
About Shri Ghansham Yamaha Motors Pvt. Ltd
6. Manufacturing
Raw Material
The manufacturing process
Quality Control
7. Bharatpur Agency
Gear
Camshaft
Body Cylinder
Head Cylinder
Axle
Connecting Rod
Crank
Crankcase Cover
8. Heat Treatment
OVERVIEW
INDIAN AUTOMOBILE INDUSTRY
Over a period of more than two decades the Indian Automobile industry has
been driving its own growth through phases. The entry of Suzuki Corporation in
Indian passenger car manufacturing is often pointed as the first sign of India
turning to a market economy. Since then the automobile sector witnessed
rapid growth year after year. By late 90’s the industry reached self-reliance in
engine and component manufacturing from the status of large scale importer.

With comparatively higher rate of economic growth rate index against that of
great global powers. India has become a hub of domestic and export business.
The automobile sector has been contributing its share has been contributing its
share to the shining economic performance of India in recent years.

With the Indian middle class earning higher per capita income, more
people are ready to own private vehicles including cars and two-
wheelers. Product movements and manned services have boosted in
the sales of medium and sized commercial vehicles for passenger and
goods transport. Side by side with fresh vehicle sales growth, the
automotive components sector has witnessed big growth. The domestic
auto components consumption has crossed rupees 9000 crores and an
export of one half size of this figure
As per Society of Indian Automobile Manufacturers (SIAM) the market share of
each segment of the industry is as follows:
 ABOUT YAMAHA MOTORS

HISTORY

Yamaha's history goes back over a hundred years to 1887 when

Torakusu Yamaha founded the company, which began producing
reed organs. The Yamaha Corporation in Japan (then Nippon Gakki
Co., Ltd.) has grown to become the world's largest manufacturer of
a full line of musical instruments, and a leading producer of
audio/visual products, semiconductors and other computer related
products, sporting goods, home appliances and furniture, specialty
metals, machine tools, and industrial robots.
The Yamaha Motor Corporation, Ltd., begun on July 1, 1955, is a
major part of the entire Yamaha group, but is a separately
managed business entity from the Yamaha Corporation. The
Yamaha Motor Corporation is the second largest manufacturer of
motorcycles in the world. Yamaha Motor Corporation owns its
wholly-owned subsidiary in the U.S. called Yamaha Motor
Corporation, USA, that is handling not only motorcycles, but also
snow mobiles, golf carts, outboard engines, and water vehicles,
under the brand name of Yamaha as well.
In 1954 production of the first motorcycles began, a simple 125cc
single-cylinder two-stroke. It was a copy of the German DKW
design, which the British BSA Company had also copied in the
post-war era and manufactured as the Bantam.
About Shri Ghanesham Motor Pvt. Ltd.

Yamaha made its initial foray into India in 1985. Subsequently,

it entered into a 50:50 joint-venture with the Escorts Group in
1996. However, in August 2001, Yamaha acquired its remaining
stake becoming a 100% subsidiary of Yamaha Motor Co., Ltd,
Japan (YMC). In 2008, Mitsui & Co., Ltd. entered into an
agreement with YMC to become a joint investor in the
motorcycle manufacturing company "India Yamaha Motor
Private Limited (IYM)".
IYM operates from its state-of-the-art-manufacturing units at
Surajpur in Uttar Pradesh and Bharatpur in Haryana and
produces motorcycles both for domestic and export markets.
With a strong workforce of more than 2,000 employees, IYM is
highly customer-driven and has a countrywide network of over
400 dealers.
RAW MATERIAL:-
The primary raw materials used in the manufacture of the body of motorcycle
are metal, plastic and rubber. The motorcycle frame is composed almost
completely of metal. The frame may be overlaid with plastic. The tires are
composed of rubber. The seat is made from a synthetic substance, such as
polyurethane.

The cylinder piston, made of aluminium alloy is an essential component of

engine. It is fitted with piston rings made of cast iron. The crankshaft and
crankcase are made of aluminium. The engine also contains a cylinder barrel,
typically made of cast iron or light alloy.

THE MANUFACTURING PROCESS:-

1. Raw materials as well as parts and components arrive at the
manufacturing plant by truck. As part of just-in-time delivery system on
which many plants are scheduled, the materials and parts are delivered at
the place where they are used or installed.
2. Manufacturing begins in the weld department with computer-controlled
fabrication of the frame from high strength frame materials. Components
are formed out of tubular metal and/or hollow metal shells fashioned from
sheet metal shells fashioned from sheet metal. The various sections are
welded together. This process involves manual, automatic and robotic
equipment.
3. In the plastic department, small plastic resin pellets are melted and
injected into molds under high pressure to form various plastic body trim
parts. This process is known as injection molding.
4. Plastic and metal parts and components are painted in booths in the paint
department using a process known as powder-coating. A powder coating
apparatus works like a large spray-painter, dispersing paint through a
pressurized system evenly across the metal frame.
5. Painted parts are sent via overhead conveyors or tow motor to assemble
department where they are installed on the frame of the motorcycle.
6. The engine is mounted in the painted frame, and various other
components are fitted as the motorcycle is sent down the assembly line.
7. Wheels, brakes, wiring cables, foot pegs, exhaust pipes, seats, saddlebags,
light, radios and hundreds of other parts are installed on the motorcycle
frame.
QUALITY CONTROL:-
At the end of the manufacturing line and assembly line, quality control
inspectors undertake a visual inspection of the motorcycle and its part’s
finishing, painted finish and fit of parts. The quality control inspectors also feel
the motorcycles with gloved hands to detect any bumps or defects in the finish.
Each motorcycle is tested on a dynamometer.
Inspectors accelerate the motorcycle from 0-60mph. During the acceleration,
the “dyno” tests for acceleration and braking, shifting, wheel alignment,
headlight and taillight alignment and function, horn function and exhaust
emissions. The finished product must meet international standards for
performance and safety. After the dyno test, a final inspection is made of the
completed motorcycle.

BHARATPUR AGENCY
The manufacturing unit of Bharatpur constitutes Casting, Machining,
Welding, Heat treatment and Painting of parts of two wheelers of IYM.
Following are the parts of two wheelers manufactures in Bharatpur Plant
of IYM:-
1. Gear
2. Axle Main
3. Cylinder Head
4. Cylinder body
5. Crank
6. Crankcase
7. Cover crankcase
8. Cam and Cam shaft
9. Connecting rod

GEAR

GEAR BLANK from the vendor is brought to the Bharatpur plant for
manufacturing of gears. Then it is passed through the following processes:-
 Turning, facing, boring and chamfering
 Hobbing
 Broaching
 Marking
  Washing
 Shaving
 Heat treatment

Hobbing
Hobbing is a machining process for making gears, splines, and spockets on a
hobbing machine, which is a special type of milling machine. The teeth or
splines are progressively cut into the gear blank by a series of cuts made by a
cutting tool called hob. Compared to other gear forming processes it is
relatively inexpensive but still quite accurate, thus it is used for broad range of
parts and quantities.
It is most widely used gear cutting process for creating spur and helical gear
and more gears are cut by hobbing than any other process since it is relatively
quick and inexpensive.

USES
Hobbing is used to make following types of finished goods:
 Cycloid gear
 Helical gears
 Involute gear
 Ratchets
 Splines
 Sprockets
 Spur gears
 Worm gears
Hobbing is used to produce most throated worm wheels but certain tooth
profiles cannot be hobbed. If any portion of hob profile is perpendicular to axis
then it will have no cutting clearance generated by usual backing off process
and it will not cut well.
BROACHING
For very large gears or splines a vertical broach is used. It consists of a vertical
rail that carries a single tooth cutter formed to create the tooth shape. A rotary
table and a Y axis are the customary axes available. Some machines will cut to a
depth on the Y axis and index the rotary table automatically. The largest gear
are produced on these machines.
Other operation such as broaching work particularly well for cutting teeth on
the inside. The downside to this is that it is expensive and different broaches
are required to make different sized gears. Therefore it is mostly used in very
high production runs.

MARKING
Marking is done on the Primary Gear and Gear Balance Weight. In this process
in mark is made on a certain distance from the centre of the gear on both types
of gear so that at time of assembly all the gear should be properly mounted
such as no misalignment is present in gear assembly, otherwise the
transmission system of vehicle fails during the operation.

CAMSHAFT

Camshafts can be made out of several different types of material. These

include Chilled iron casting and Billet steel.
Chilled Iron Casting: this is a good choice for volume production. A chilled iron
camshaft has a resistance against wear because the camshaft lobes have been
chilled, generally making them harder.
Billet Steel: when a high quality camshaft is required, engine builder and
camshaft manufacturers choose to make the camshaft from steel billet. One
example being EN40b. When manufacturing a camshaft from EN40b, the
camshaft will also be heat treated via gas nitriding, which changes the micro-
structure of the material. It gives a surface hardness of 55-60 HRC. These types
of camshafts can be used in high-performance engines.
Processes
Various process involve in the manufacturing of cam shaft according to
operating machines are:-
 Facing
 Turning operation
 Keyway drilling and tapping operation
 Oil hole drilling operation
 Cam grinding operation
 Grinding operation
 Lapping operation
 Washing operation

BODY CYLINDER

Body of cylinder of engine in made of aluminium in Casting shop of Bharatpur

plant. In casting liquid aluminium is poured into the mold, which contains the
hollow cavity of desired shape, and then allowed to solidify. The solidify part is
known as casting which is ejected or broken out of the mold to complete the
process.
Initially it has poor surface finish and defects, so it is brought to the Machining
shop for giving desired accurate dimension and surface finish.
Machine/Operator-wise operation done on the Body cylinder are:-
 Camera Vision testing
 Face milling, drilling and boring  A face
 Milling, dowell and drilling  B face
 Milling, drilling and tapping  C face
 Dowell and rough boring  B face
 Fine boring
 Internal diameter honing
 Internal diameter testing
 Air plug gauge setting
 Oil extracting machining
 Date code marking
 Washing and air cleaning
 Leak testing
HEAD CYLINDER

Like Body cylinder it is also made up of Aluminium in casting shop and

according to its desired shape then it is also brought to the Machine shop for
removal of defects, giving more accurate dimension and surface finish.
Machine-wise process involve in the manufacturing of Head cylinder are:-
 Spot facing and drilling
 Milling and drilling
 Right fixture Exhaust facing, rough guide hole drilling & Left side inlet
facing/guide hole drilling
 Right side exhaust, left side inlet facing and threading
 Right side exhaust, left side exhaust boring and threading
 Right side facing, left side inlet facing, drilling and tapping
 Right side exhaust, left side inlet rocker milling
 Right side exhaust, left side inlet parent boring
 Parent bore inspection
 Right side spark hole facing, threading, left side hole drilling and reaming
 Rough cambore, face milling, drilling and threading
 Mid-washing
 Air blow procedure
 Air plug gauge inspection
 Seat and guide press
 Exhaust valve seat machining
 Inlet valve seat machining
 Cambore fine boring, drilling and reaming
 Deburring
 Final washing
 Air blow procedure
 Leak inspection
AXLE MAIN

The method includes heating a billet at a heating station to a predetermined

temperature, forging the heated billet at a forging station to form a machined
axle. This axle is brought to the Bharatpur plant from vendor and processed
in machining shop for desired accurate shape, dimension and surface finish.
The process involves are:-
 Turning
 Deburring
 Drilling
 Oil hole drilling
 Washing
 Hobbing
 Threading

CONNECTING ROD

A standard shape of connecting rod with poor surface finish is brought from
vendor to the Bharatpur plant where whereas operation is done on it in
Machining and heat treatment shop to give it proper accurate dimension, good
surface finish and hardness.
 Operation carried out in Machining shop are:-
 Small end drilling
 Small end internal diameter drilling
 Small end champering
 Big end boring and champering
 Small end oil hole drilling

 Heat treatment: In heat treatment shop for carburizing it is kept for 9 hours at 930 degree
celsius and then for diffusion it is kept for 4 hours
Then again it is brought to the machine shop for:
 Both end face grinding
 Honing
 Washing

CRANK

Like some other parts forged crank is also bought from vendor of standard
shape and poor surface finish. In machining shop it various operations are
done on it to give it a defect less and accurate dimension and also good
surface finish. The machine-wise operations done over it are:-
Centering and facing
Pin turning
Pin hole boring
Thread rolling
Keyway milling
Induction hardening
Outer diameter grinding
Thrust facing
Internal diameter grinding

COVER CRANKCASE

Like engine cylinder it is also manufactured in casting shop of Bharatpur plant

by melting the metal and poring it into the mold and then extracting the
solidify casting from the the mold. From casting shop this cover crankcase is
brought to the machine shop for the following process to give it a good surface
finish and preparing its desired dimensions:-
 Milling, dowell and boring
 Drilling, tapping, boring of screw hole
 Drilling and chamfering
 Washing
 Air-blow
 Visual inspection
 HEAT TREATMENT
Heat treating is a group of industrial and metal working processes used to alter
the physical and sometimes chemical properties of a material. The most
common application is metallurgical. Heat treatments are also used in the
manufacture of many other materials such as glass, Heat treatment involves
the use of heating or chilling normally to extreme temperatures to achieve a
desired result such as hardening or softening of material. Heat treatment
techniques include annealing, case hardening, precipitation strengthening,
tempering and quenching. It is noteworthy that while the term heat treatment
applies only to processes where heating and cooling are done for specific
purpose of altering properties intentionally, heating and cooling often occur
incidentally during other manufacturing processes such as hot forming or
welding.

TECHNIQUES:
The heat treatment techniques used for manufacturing of parts of two wheeler
in Bharatpur plant are:-
Annealing
It consists of heating a metal to a specific temperature and then cooling at a
rate that will produce a refined microstructure. It is often used to soften a
metal for cold working to improve machinability or to enhance properties like
electrical conductivity.
Normalizing
Normalizing is a technique used to provide uniformity in grain size and
composition throughout an alloy. The term is often used for ferrous alloys that
have been heated above the upper critical temperature and then cooled in
open air.
Stress relieving
Stress relieving is a technique to remove or reduce the internal stresses created
in a metal. These stresses may be caused in a number of mays, ranging from
cold working to non-uniform cooling. Stress relieving is usually accomplished by
heating a metal below the lower critical temperature and then cooling
uniformly.
Aging
Some metal are classified as precipitation hardening metals. When a
precipitation hardening alloy is quenched, its alloying elements will be trapped
in solution, resulting in a soft metal. A “solutionized” metal will allow the
alloying element to diffuse through the microstructure and form intermetallic
particles. These intermetallic particles will nucleate and fall out solution and act
as a reinforcing phase, thereby increasing the strength of the alloy. Alloys may
age “naturally” meaning that the precipitates form at room temperature, or
they may age “artificially” when precipitates only form at elevated
temperatures. In some applications, naturally aging alloy may be stored in a
freezer to prevent hardening until after further operation-assembly of rivets,
for example, may be easier with a softer part.

Quenching
Quenching is a process of cooling a metal very quickly. This is most often done
to produce a martensite transformation. In ferrous alloys, this will often
produce a harder metal, while non-ferrous alloys will usually become softer
than normal.