Internship Project Report

Nexon Power-Train Assembly & Critical to Qaulity Parameters.

Quality Analysis of Outsourced Parts.

At
Tata Motors Passenger Vehicle Ltd
By
VIJAY KUNDLIK SUTAR
(Department of Mechanical Engineering)
VIDYA NIKETAN COLLEGE
OF ENGINEERING,
SANGAMNER

Under the Guidance of

Mr. PRAKASH WAKCHAURE
 DECLARATION

I declare that this written submission represents my ideas in my own words. I

also declare that I have adhered to all principles of academic honesty and
integrity and have not misrepresented or fabricated or falsified any
idea/data/fact/source in my submission. I understand that any violation of the
above will be cause for disciplinary action by the Institute and can also evoke
penal action from the sources which have thus not been properly cited or from
whom proper permission has not been taken when needed.

- VIJAY SUTAR
 ACKNOWLEDGMENTS

The success and result of this project requires a lot of guidance and
endorsement from many persons, and I am fortunate to get all of this
throughout my entire internship project. I was able to accomplish this
project only with such assistance and supervision and therefore, I will never
forget to thank them. I take this opportunity to express my deepest
gratitude and special thanks to Mr. Satish Joshi (Project guide) who despite
being extraordinarily busy with their work schedule, took time out to hear,
guide me and keep me on the correct path during this project tenure. I owe
my deep gratitude to Mr. Satish Joshi & Mahesh Paithane Sir for giving
necessary advice and guidance all through the time and being a constant
support, which helped me complete the project on time. I choose this
moment to acknowledge their contribution gratefully . I would like to pay
my sincere thanks to the HR department at TATA Motors, especially Mr.
Manoj Yadav , for providing me with this once-in-a-lifetime opportunity to
enrich my knowledge and skill set in such an esteemed organization. I
perceive this opportunity as a big milestone in my career development. I
will strive to use the gained skills and knowledge in the best possible way,
and I will continue to work on the improvements to attain desired career
objective.

Last but not the least, I would like to thank all those who helped me directly
or indirectly during this training period.

- VIJAY KUNDLIK SUTAR

Highlights of The Study:
• Duration of Internship –
19 January 2023 to 19 April 2023
• Name of Organization –
Tata Motors Passenger Vehicle Ltd. (TMPVL)
• Location –
Chikhli, Pune- 411019
• Project Guide Name:
Mr. Satish Joshi

Mr. Satish Joshi

(Senior Manager VQA- PWT, TMPVL )
1 Introduction Page
2 About VQA 3
3 Power-Train Overview 5

4 Engine Overview 6

5 Crankshaft Process Flow 13

6 Camshaft Process Flow 10

7 Cylinder block Process Flow 16

8 Cylinder Head Process Flow 20

9 Engine Assembly Main Line 29

10 Different Parts Engine and their functions 26

11 Transaxle Overview 31
12 Layout of TA Department 32
13 About Transaxle 33
14 Different Parts in TA and their functions 34
15 Critical Parameter testing 35
16 Gearbox testing 37
17 Soft Shop and hard shop Process 38
18 Soft Shop Process flow 39
19 Hard Shop Process Flow 40
20 Heat Treatment Process Flow 41
21 Assembly Process Flow 42
22 Quality Analysis of Outsourced Parts 43
23 Gear CTQ Parameter Testing 44
24 Hoffler Gear Report 46
25 Housing CTQ Parameter Testing 50
26 Gear Shifter CTQ Parameter Testing 51
27 Piston Cooling Nozzle Testing 53
28 Oil Pump CTQ Testing 54
29 Part Inspection & Development 55
30 Instruments used for inspection 56
31 Surface Roughness tester 57
32 Millipore Testing 58
33 Quality Tools used at shop floor 59

1|Page
List of Abbreviations –
Abbreviation Definition
OD Outer Diameter
ID Inner Diameter
Amt Automated Manual Transmission
fa Total Profile Deviation
ffa Profile Form Deviation
fha Profile Slope Deviation
fhβ Total Helix Deviation
ffβ Involute Profile of Gear
Fβ Total Form

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Introduction

Tata Motors Passenger Vehicle Ltd, Pune

The Pune facility of Tata Motors is in the Pimpri-Chinchwad industrial belt of Maharashtra.
The state-of-the art R&D centre in this facility sets the benchmark for automotive research
and development in India. The Pune facility also houses some of the best manufacturing
facilities in the automotive industry; for example, its Product Engineering Division has one of
the biggest and the most versatile tool-making divisions in the country.

The most versatile of Tata Motors' manufacturing plants, the Pune facility is a full range
supplier of both commercial and passenger vehicles. It boasts of delivering more value per vehicle,
since it is a highly vertically integrated plant as regards to core processes such as engines, gear box,
paint shop, etc. Six assembly lines cope with the diverse range of vehicles that roll out of the plant,
like HMCV, ILCV trucks, ICV bus chassis, ICV Ultra range trucks and bus chassis, UVs, pickups, Winger
vans, SUVs, etc. Tata Motors' range of Defence vehicles are also produced here.

Tata Motors' passenger vehicles plant in Pune is one of the most advanced manufacturing
facilities in India. With two flexible assembly lines, the plant has a capacity of producing 1,000
cars per day, working on a double shift. The facility has introduced many popular models like
Safari, Harrier, Tiago, Tigor, Punch and Nexon

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About VQA
VQA (Vendor Quality Assurance) deals with each & every product that goes into a Transaxle
or engine, from a small dowel to housing or gears. The Department deals with various
suppliers and internal departments to deliver the best quality in every product that rolls out
of the line, functions of VQA includes: -

• Performance Monitoring
• New Development Product Quality Assurance
• Corrective Actions for every CTQ
• Benchmarking of every component

Hierarchy

Market Research

Purchase & Costing Advance Quality

VQA

Production Planning Control

Maintenance Manufacturing Logistics

Operations Quality

Customer

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Powertrain Shop Overview

Powertrain is a system inside a vehicle, boat or another type of machinery. The system is designed to propel
the vehicle forward. In a car, a powertrain consists of the engine or motor and its internal components, such
as the energy storage system, transmission and driveshaft. In a conventional internal combustion engine
(ICE), the powertrain converts thestored gasoline or diesel energy to kinetic energy in the engine and
transfers it via the transmission, driveshaft and differential as torque to the wheels of the vehicle, propelling it
forward.Nexon, Altroz, Tiago, Tigor, Punch is manufactured in the department.

 PWT shop has 2 assembly lines dedicated to different models assembled

here,TA6300(Nexon) & TA65* . There are the two lines, out of which TA6300
assembles all Nexon variants and AltrozDieselwhile TA 65* assembles gearboxes for Punch,
Tiago, Tigor.
 The Power Train Department is divided into 2 main shop floors which are-
- Engine Shop
- Transaxle Shop

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Engine Shop Overview

It is a complex machine built to convert heat from burning gas into the force that turns
theroad wheels.
The chain of reactions which achieve that objective is set in motion by a spark , whichignites a
mixture of petrol vapour and compressed air inside a momentarily sealed cylinder and causes
it to burn rapidly. That is why the machine is called an internal combustion engine . Asthe
mixture burns it expands, providing power to drive the car. To withstand its heavy workload,
the engine must be a robust structure. It consists oftwo basic parts: the lower, heavier section
is the cylinder block, a casing for the engine'smain moving parts; the detachable upper cover is
the cylinder head .
The cylinder head contains valve-controlled passages through which the air and fuel
mixtureenters the cylinders, and others through which the gases produced by their
combustion are expelled.

The block houses the crankshaft , which converts the reciprocating motion of the pistons intorotary
motion at the crankshaft. Often the block also houses the camshaft , which operates mechanisms
that open and close the valves in the cylinder head. Sometimes thecamshaft is in the head or
mounted above it.
Nexon, Altroz is manufactured in the department.

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Engine Shop Overview
It is a complex machine built to convert heat from burning gas into the force that turns the
road wheels.
The chain of reactions which achieve that objective is set in motion by a spark , which ignites
a mixture of petrol vapour and compressed air inside a momentarily sealed cylinder and
causes it to burn rapidly. That is why the machine is called an internal combustion engine . As
the mixture burns it expands, providing power to drive the car.
To withstand its heavy workload, the engine must be a robust structure. It consists of two
basic parts: the lower, heavier section is the cylinder block, a casing for the engine's main
moving parts; the detachable upper cover is the cylinder head .
The cylinder head contains valve-controlled passages through which the air and fuel mixture
enters the cylinders, and others through which the gases produced by their combustion are
expelled.
The block houses the crankshaft , which converts the reciprocating motion of the pistons into
rotary motion at the crankshaft. Often the block also houses the camshaft , which operates
mechanisms that open and close the valves in the cylinder head. Sometimes the camshaft is
in the head or mounted above it.

Nexon, Altroz is manufactured in the department.

7|Page
Engine Shop Overview
Most automotive engines are piston (reciprocating) internal combustion engines.
Automotive engines are divided into four-cycle and two-cycle engines according to
the working process and are divided by the method of fuel ignition into spark plug
ignition engines (also known as carburettor engines or gasoline engines) and diesel
engines, which are self-ignition engines using high-temperature air compressed
within the engine cylinders. The fuel mixture of vaporized gasoline and air, blended in
the carburettor, is admitted to the cylinders of carburettor piston engines. Piston
engines without carburettors also exist; these are equipped with a device for direct
injection of fuel into the intake manifold or into the engine cylinder.
Modern four-cycle piston engines consist of a cylinder block usually made integrally
with the crankcase, the cylinder head, pistons with sealing rings and oil-control piston
rings, connecting rod, crankshaft, flywheel, camshaft, spring-loaded intake and
exhaust valves, valve train parts (rocker arm, valve lifter), the drive connecting the
crankshaft and camshaft, spark plugs or fuel nozzle, and so on. These engines are
equipped with a radiator and fan for the cooling system. They have pumps for forced
circulation of lubricant oil and cooling fluid and for bringing fuel from the fuel tank, as
well as fuel filters, oil filters, and air cleaners, a starter or cranking motor, ducts for
air, gas, fuel, oil, and cooling fluid, and automatic control devices controlling the
frequency of rotation of the crankshaft and the temperature of the cooling fluid and
fuel mixture.

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Camshaft

A camshaft is a rod which rotates and slides against a piece of machinery in order to
turn rotational motion into linear motion. This change of motion is accomplished by
the camshaft moving further and closer from the axis of rotation as the camshaft is
pushed by the machinery. These moving pieces of the shaft are the cams. The linear
distance moved is called the 'throw'.
A camshaft on an internal combustion heat engine is a device that controls both the
input of fuel and the expulsion of exhaust fumes. It consists of several radial cams,
each displacing intake or exhaust valves. This camshaft is connected to the
crankshaft via belt, chain or gears. This ensures consistent timing of the valves in
relation to the motion of the pistons.
The function of a camshaft is dependent on how a valve works and the function of
the cam itself. A valve on a cylinder head consists of two basic parts, a stem and a
head. The head plugs the nozzle that allows fuel intake or exhaust flow and requires
linear motion .A cam, in its simplest definition, is a mechanical link that converts
rotational motion into linear motion, or vice versa. The cams on a camshaft achieve
this displacement by the rotation of a radial pattern, and a follower which moves
perpendicular to the rotational axis. The cam pattern on a camshaft is non-circular
with a single lobe. The follower matches the displacement of the cam as it rotates.
This displacement is then translated to the stem of the valve, allowing head to rise as
the lobes of the cam pass through the follower.
Since an automotive engine has several pistons like the piston in, a single cam is
insufficient for all of these pistons. An entire rod covered with cams must be used.
Note that the precise placement of the cams along the shaft allow for precise timing
of the relative valves opening and closing. This precise timing is needed since a car
engine is firing at thousands of RPM. Insuring the timing is proper in a car engine is
one of the simpler ways to save money and energy.

9
Camshaft Machining Process:

Soft Finished Camshaft

Landis Grinding Machine

Superfinishing Machine

Slot Milling Machine

Crank Checking Machine

Camshaft washing Machine

Inspection Unit

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Camshaft Machining Process (Operation Description)

1. Lobe Grinding: Abrasive wheel cutting of small chip from the workpiece via
shear deformation used to show high surface quality (e.g. low surface
roughness) and high accuracy of shape and dimension. It is very compact,
high precision, very stable for high accuracy production runs of cam shafts
with convex and concave cam forms.
2. Superfinishing Machine: Lapping of all lobe, bearing diameter & oil seal
diameter. Lapping is the machining process in which two surfaces are
rubbed together with an abrasive between them. Type of precision finishing
machine. Lapping involves the use of an abrasive mixture to create friction
between the lap plate and workpiece, grinding on other hand is a
machining process that uses an abrasive wheel to smoothen a surface.
3. Slot Milling: Slot milling is a type of milling operation in which a rotating
cutting tool is used to remove material from a workpiece by moving it in
and out of a slot. This type of milling is typically used to create keyways,
slots, or pockets. Compared to other milling operations, slot milling is
typically used to cut deeper slots or pockets than what can be achieved
with end milling for example. Additionally, it often produces a cleaner and
an excellent surface finish.
4. Magnaflux Crack Checking: By using Magnaflux equipment, materials, and
accessories you are able to locate such inherent and processing defects as:
inclusions, seams, laminations, shrinks, cracks, hot tears, laps, flakes,
welding defects, heat treat and grinding cracks, machining tears,
quenching and straightening cracks and also fatigue or service cracks on
parts from service.

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 Crankshaft

A crankshaft is a rotating shaft that converts reciprocating motion of a piston

into a rotational motion. It’s commonly used in internal combustion engines to
perform such operation. Crankshafts consist of series of cranks and crankpins
to which the connecting rods are attached.
A crankshaft with at least one shaft rotates within the engine block. It rotates
using the main bearings. The crankpins rotate within the connecting rods using
rod bearings.
The crankshaft is fitted into the engine block through it’s main journals. The
connecting rods are fixed on the conrod journals of the crankshaft. On opposite
sides of the conrod journals the crankshaft has counterweights which
compensates outer moments, minimises internal moments and thus reduces
vibration amplitudes and bearing stresses.. At one end of the crankshaft the
flywheel is connected and on the other end the valve timing gearing.

1. Control side or drive end

2. Counterweights
3. Main bearing journal
4. Conrod journal
5. Flywheel side/force transfer
6. Oil bore
The number of main journals and conrod journals depends on the number of
cylinders and the type of the engine (V-type, straight, etc.). On both main
journal and conrod journals, the crankshaft has lubrication orifices (oil bore)
through which oil flows when the engine is running

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Crankshaft Machining Process:

Lapping

Washing

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Crankshaft Machining Process (Operation Description)

1. Facing: Facing is the operation of machining the end of the rotating axis.
During the facing, the tool moves along the radius of the workpiece to
produce the desired part length and a smooth surface by removing a thin
layer of material.
2. Centering: Centering operation lathe, centering is the process of hold the
job in a work holding device chuck, drive plate and face plate on center of
lathe machine. It is required to turn any job concentric to lathe centers for
cylindrical machining.
3. Mass Centering: Mass centering eliminates these initial unbalances by
matching the rotors rotational (Geometric axis) with its main inertia axis &
by centering it in this axis. The amount of initial unbalance of the finished
crankshaft decreases dramatically.
4. Turning: Turning is a form of machining, a material removal process, which
is used to create rotational parts by cutting away unwanted material. The
turning process requires a turning machine or lathe, workpiece, fixture and
cutting tool. Turning is used to produce rotational, typically axi-symmetric,
part that have many features, such as holes, grooves, threads, tapers,
various diameter steps and even contoured surfaces.
5. Lobe Grinding: Abrasive wheel cutting of small chip from the workpiece via
shear deformation used to show high surface quality (e.g. low surface
roughness) and high accuracy of shape and dimension. It is very compact,
high precision, very stable for high accuracy production runs of cam shafts
with convex and concave cam forms.
6. Milling: Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a workpiece. This may be done by
varying direction on one or several axes, cutter head speed, and pressure.
Milling covers a wide variety of different operations and machines, on
scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes for machining
custom parts to precise tolerances.

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1. Drilling: Drilling is a cutting process where a drill bit is spun to cut a hole
of circular cross-section in solid materials. The drill bit is usually a rotary
cutting tool, often multi-point. The bit is pressed against the work-piece
and rotated at rates from hundreds to thousands of revolutions per minute.
2. Induction Hardening: Induction hardening is a heat-treating process used
to increase the hardness or wear resistance of a material. Induction
hardening heats a material using a form of induction heating to a specific
temperature. Once the temperature is reached, it is rapidly cooled by a
quenching media. This rapid cooling forms a material microstructure that is
hard and strong.
3. Lobe Grinding: Abrasive wheel cutting of small chip from the workpiece via
shear deformation used to show high surface quality (e.g. low surface
roughness) and high accuracy of shape and dimension. It is very compact,
high precision, very stable for high accuracy production runs of cam shafts
with convex and concave cam forms.

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Cylinder Block:

The cylinder block is the central component of any engine. It has to be of the
highest possible quality so that it can perform its vital role in the operation of
the cylinder heads, timing case, sump and flywheel.
Cylinder blocks are specially designed to withstand a variety of temperatures
and loads to maintain the stability and lubrication of each individual engine.
Each block has a number of oil galleries to transfer oil throughout the engine,
thereby maintaining the lubrication of all the critical components. The block
also contains the water galleries needed to provide cooling to the engine to
maintain its optimum operating temperature.
A typical cylinder block unit is made up of a number of cylinders, depending on
the type and specification of the engine model being built, and it will include
cylinder walls, coolant passages and cylinder sleeves.
The cylinder block is a structure that contains the cylinders, and other engine
parts of an internal combustion engine.

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Cylinder Block Exploded view:

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Cylinder Block Machining Process:

Burr / Sand Removal

Core Plug Apply

Blow by Leakage test

Sump face finishing

Main bearing Apply

Head, Rear, Front face finishing

Torque Plate Apply

Honing Apply

Torque Plate Removal

Washing (Deburring)

Final Inspection
(Visual, Dimensional)

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Page | 19
Cylinder Head:

The cylinder head is a three-piece assembly consisting of a lower member that

contains the gas passages, serves as a mounting for the injector valves and the
ignition plug, and forms part of the combustion chamber. The cylinder head
itself is a piston-like member retained by a flange held by eight screws to the
lower member. The cylinder head is sealed against gas leakage by a metallic lip
seal. This configuration readily allows for the experimental changing of the
combustion chamber shape by substituting a relatively inexpensive insert
instead of changing the complete head.
The cylinder head also holds the injectors and valves – and contains more
moving parts than any other part of the engine.
Although largely unnoticed, the cylinder head plays a key role in your engine.
It’s a solid item that sits at the top of your unit and covers its workings. It’s
sealed in place with the head gasket.
The inside of the cylinder head contains a number of passages – known as
ports or tracks – and the air mix travels along these to the inlet valves. Other
tracks inside the cylinder head are the route by which the exhaust gases travel
when leaving the main engine block.

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Cylinder Head Process Flow

Front face; Rear face finishing

Valve Seat Pressing

Valve Guide Pressing

Cam Cap Assembly

Vacuum Pump Assembly

Visual Inpection

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Engine:

Tata Motors Passengers Vehicle Ltd (TMPVL) assemble 2 types of engine 1.5l
Diesel Nexon Engine, 1.5l Diesel Altoz Engine. It is a complex machine built to
convert heat from burning gas into the force that turns the road wheels.
The chain of reactions which achieve that objective is set in motion by a spark ,
which ignites a mixture of petrol vapour and compressed air inside a
momentarily sealed cylinder and causes it to burn rapidly. That is why the
machine is called an internal combustion engine . As the mixture burns it
expands, providing power to drive the car.
Tata engine is made by more than 500 parts in which more than 50 parts are
considered to be critical such as Piston, Connecting rod, Flywheel, Intake
manifold and much more.

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Different parts in Engine

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Different parts in Engine and their Functions:
Piston: A piston is a moving disk enclosed in a cylinder which is made gas-
tight by piston rings. The disk moves inside the cylinder as a liquid or gas
inside the cylinder expands and contracts. A piston aids in the
transformation of heat energy into mechanical work and vice versa.
Because of this, pistons are a key component of heat engines. Pistons work
by transferring the force output of an expanding gas in the cylinder to a
crankshaft, which provides rotational momentum to a flywheel. Such a
system is known as a reciprocating engine.
Connecting Rod: A connecting rod, also called a 'con rod', is the part of a
piston engine which connects the piston to the crankshaft. Together with
the crank, the connecting rod converts the reciprocating motion of the
piston into the rotation of the crankshaft. The connecting rod is required to
transmit the compressive and tensile forces from the piston. In its most
common form, in an internal combustion engine, it allows pivoting on the
piston end and rotation on the shaft end. The predecessor to the
connecting rod is a mechanic linkage used by water mills to convert
rotating motion of the water wheel into reciprocating motion.
Oil Sump: The oil sump contains the engine oil required for lubrication. The
oil is extracted from it by an oil pump and conveyed into the engine block’s
oil ducts via the oil filter. The oil then flows back into the oil sump from the
lubrication points. The oil sump is generally bolted on at the lowest point of
the engine, below the crank mechanism on the crankcase. It features an oil
drain plug, the opening of which in the oil sump allows the oil to drain out
when changed.
Flywheel: heavy wheel attached to a rotating shaft so as to smooth out
delivery of power from a motor to a machine. The inertia of the flywheel
opposes and moderates fluctuations in the speed of the engine and stores
the excess energy for intermittent use.

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Torsional Vibration Dampers: Torsional Vibration Dampers absorb
rotational vibrations in internal combustion engines. The dampers are
particularly effective in conjunction with decoupled pulleys, which keep
crankshaft irregularities away from the belt drive and auxiliaries.
Oil Filter: The oil filter helps remove contaminants from your car engine's
oil that can accumulate over time as the oil keeps your engine clean. Clean
motor oil is important because if the oil were left unfiltered for a period of
time, it could become saturated with tiny, hard particles that can wear
surfaces in your engine.
Alternator: The alternator is a generator whose purpose is to distribute
electricity to the car and recharge the battery. Outside of some hybrid
models, all vehicles with a standard internal combustion engine will have
an alternator. The alternator is normally connected to the engines crank
pulley by a rubber belt. As the engine rotated, the belts turn the alternators
rotor inside the stator. Both the stator and rotor are made from wound
copper and electrical steel.
Throttle: In an internal combustion engine, the throttle is a means of
controlling an engine's power by regulating the amount of fuel or air
entering the engine. In a motor vehicle the control used by the driver to
regulate power is sometimes called the throttle, accelerator, or gas pedal.
Fuel Rail: The fuel rail supplies fuel to the fuel injectors mounted directly
on the fuel rail. That the fuel is available at the required injection pressure
at the start of injection and only minimal pressure fluctuations occur
between the individual injections is key. For the gasoline port fuel injection,
fuel rails made of plastic or stainless steel are available.
Intake Manifold: The primary function of the intake manifold is to evenly
distribute the combustion mixture (or just air in a direct injection engine) to
each intake port in the cylinder head(s). Even distribution is important to
optimize the efficiency and performance of the engine.

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EGR Module: Exhaust Gas Recirculation (EGR) is an efficient, cost effective
system for reducing automotive nitrogen oxide (NOx) emissions. The high-
pressure EGR loop collects part of the exhaust gases at the cylinder head
outlet and re-injects them into the engine air intake. The main benefit is
that NOx is reduced at the source by limiting the quantity produced during
the combustion process, rather than by post-treating the exhaust gases.
AC Compressor: The compressor is the power unit of the air-conditioning
system that puts the refrigerant under high pressure before it pumps it into
the condenser, where it changes from a gas to a liquid. A fully functioning
compressor is necessary for the air-conditioning system to provide peak
performance.
Turbocharger: The job of the turbocharger to compress more air flowing
into the engine's cylinder. When air is compressed the oxygen molecules
are packed closer together. This increase in air means that more fuel can
be added for the same size naturally aspirated engine.
Clutch Plate: The clutch plate helps to overcome the inertia and start the
vehicle moving. When the automobile engine develops power that is
transmitted via clutch as a twisting force (torque) from the engine
crankshaft to driving wheel.

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Trim Line:

Multiple Bracket

Support Bracket (Turbocharger)

Intermediate Shaft Bracket

Dip Stick & Starter Motor Assembly

Catcon Assembly

Finished

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 Crankshaft (Finished) Cylinder Block (Finished) Cylinder Head (Finished)

Final Washing

Valve Seal Press

machine

Intake Valve Lock Half Press

block

Exhaust Valve Lock Half Press

Crankshaft RI & Axial Play Check

Machine
Valve Oscillation Machine

Piston, Connecting Rod fitting

Piston & Connecting Rod Assembly Valve Collect Check Machine
Assembly

Valve Leak Test Machine

Flywheel Tortional Damper Cylinder Head Drop

Throttle Fitting 2 Camshaft Assembly on Cylinder

T map Fuel Rail Intake Manifold Assembly
Head

Timming Cover Assembly Cover Assembly Cylinder Head Mount Assembly 1.

2.
3.

Belt Assembly (AC Comp to

Turbocharger Bracket Assembly (AC Compressor) EGR Mo
Alternator)

Heat Shield (Turbocharger & Exhaust

Hose (Oil Separator to Air Intake) Hose (Thermostat to Radiator) 1.
Manifold)
2.
Turbocharger

Cleaning room
Clutch Plate Assembly Wire Connection One Way Check Valve
(Injector & Hp Pipeline)

False True
Testing Trim Line

30
 .
Transaxle Shop Overview

Transaxle shop is utilized for the assembly of various gearboxes of different class of vehicles.
The transaxle department manufactures gearboxes for 5 models (both manual and
automatic) of Tata passenger vehicle lineup. TA for Nexon, Altroz, Tiago, Tigor, Punch is
manufactured in the department.

TA shop has 2 assembly lines dedicated to different models assembled here,

• TA6300
• TA65*
There are the two lines, out of which TA6300 assembles all Nexon variants and Altroz Diesel
while TA 65* assembles gearboxes for Punch, Tiago, Tigor.
The Transaxle Department is divided into 4 different shop floors which are-

• Soft shops
• Heat treatment shop
• Hard Shop
• Assembly

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Layout of Transaxle Department

Soft Shop Quality Department Blank Condition Material

Inward Area

Soft shop
Storage

Heat Treatment Shop

Hard Shop Material

Unloading Area

Assembly

TA65* Assembly TA6300 Assembly

Material Logistics
Storage

Area

VQA

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About Transaxle

A single unit combining transmission gearbox, clutch, final drive, and differential are
combined into a single unit connected directly to the driveshaft.

The transaxle is an assembly of various mechanical elements which combined to give

different power ratios output to wheels.

There may be changes in different parts involved in transaxle based on the fuel type of the
car or based on the transmission whether it’s a manual or an AMT but the whole sole
purpose remains the same to provide different output ratios ensuring a smooth output
power delivery.

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Different Parts of Transaxle
• Housing
 Front
 Rear
• GFD (Gear Final Drive)
• Input Shaft
• Lay Shaft
• RI Gear
• Gear Shifters
• Clutch Plate Bearing
• Gear Shifter Cables
• AMT gear shifter kit (only in AMT models)

Functions of different parts in Transaxle –

• Housing – The 2-part front and rear combines to form a housing, the gear housing is
a mechanical housing that surrounds the mechanical components of a gear box. It
provides mechanical support for the moving components, a mechanical protection
from the outside world for those internal components, and a fluid-tight container to
hold the lubricant that bathes those components.

• GFD (Gear Final Drive) – It’s a gear arrangement that permits power from the engine
to be transmitted to a pair of driving wheels, dividing the force equally between
them but permitting them to follow paths of different lengths, as when turning a
corner or traversing an uneven road.

• Input Shaft - The input shaft is connected directly to the engine and turns at the
engine speed. It brings the drive into the gearbox system and withstands the torque
generated by engaged gears. The output shaft carries the power from the input shaft
and runs at different speeds, depending on the gears and gear ratio.

• Lay Shaft - A layshaft is an intermediate shaft within a gearbox that carries gears but
does not transfer the primary drive of the gearbox either in or out of the gearbox.

• RI Gear- A reverse idler gear is used to reverse the normal direction of rotation of
the main or output shaft so that the automobile can be moved backward.

• Gear Shifter – It’s a mechanical device consisting of a shifter and a doc attached on a
rod, the shifter is in contact with the gears and shifts the gear based on the input
received.

Page | 34
 • Clutch Plate Bearing - The clutch plate bearing is what makes the whole clutch
process work. It is responsible for allowing the clutch to engage the engine and
disengage the engine. The bearing rides on the clutch spring and connects the
gearbox's release mechanism to the pressure plate.

• Gear Shifting Cables - Gear shift cables are integral parts of every vehicle and are
used to link the transmission and gear lever, these cables carry the input given to the
gear lever.

• AMT gear shifting kit – This type of kit is used in automatic transmission, this kit
decides the right gear for the car to be in based on the various parameters like
engine rpm, speed, brake paddle condition, accelerator input. It consist of a
Transmission Control Unit (TCU) which is connected to ECU of the car, TCU sends
electronic signals that result in operation of hydraulic actuator which changes the
gear.

Critical Parameter Testing

The Components that combine to form a gearbox are very critical to quality. Material quality and
dimensionality are some of the key aspects to components quality. So here are some
methodologyand testing conditions that various parts need to undergo to pass quality check

Page | 35
Sr. Part Name Parameter Description
no
Damage A Housing is first checked for any deformations or
damage or if any cracks are there in the body.
1. Housing Surface Roughness Surface roughness of all the machined surfaced are
check with respect to the standards assigned.
Dimensional All the dimensional parameters like thickness, hole
Parameters OD ID, or depth, etc. are checked wrt to the
standards set.
Dimensional Shaft is first checked for all the dimensions like OD,
Parameters Depth against the standards set.
Gear Profile Checked in hoffler for parameters like Fa, ffa, fha,
R/T-Φ
Lead Checked in hoffler for parameters like FHβm, Fβ,
2. Input Shaft/ Lay
ffβ, fhβ
Shaft
Gear Spacing Checked in hoffler for parameters like fp max,fu
max, Rp, Fp, Fpz/8
Runout Checked in hoffler for parameters like pitch line
runout Fr, Rs (variation of tooth thickness)
Dimensional Checked in hoffler for parameters like module,
specification Pressure angle, helix angle, pitch circle diameter.

Dimensional GFD is first checked for all the dimensions like OD,
Parameters Depth against the standards set.
Gear Profile Checked in hoffler for parameters like Fa, ffa, fha,
R/T-Φ
3. GFD/ Any
Lead Checked in hoffler for parameters like FHβm, Fβ,
finished gear
ffβ, fhβ
Gear Spacing Checked in hoffler for parameters like fp max,fu
max, Rp, Fp, Fpz/8
Runout Checked in hoffler for parameters like pitch line
runout Fr, Rs (variation of tooth thickness)

Dimensional Checked in hoffler for parameters like module,

specification Pressure angle, helix angle, La, Lβ, Base circle
diameter, face width.
Dimensional Checked on a designed fixture against set standards,
Parameter parameter like distance between doc tofork face
distance, face to datum distance.
4. Gear Shifters Doc straightness Checked on fixture with go, no go gauge
Checked with the gauge by taking reading at
Straightness different set points and comparing with set
standards
Perpendicularity Checked on a gauge by taking reading at fork side
wrt the axis which is the shaft and comparing with
the set standards.

Page | 36
Gearbox Testing –
Once a Transaxle is assembled it goes from various testing phases where it’s been tested for load,
noise, irregularities. The tests that a TA undergoes are as follows: - - Air Leak Test
In air leak test the gearbox is filled with air and pressure is checked to insure if there are any
leakages in the whole gearbox, acceptable range for manual and automatic TA is different as they
vary in sizes.
Manual 0 – 8 𝐶𝑚3/𝑚𝑚
AMT 0 – 15𝐶𝑚3/𝑚𝑚

If the TA fails in the air leak test, then the TA has to undergo water dip test, in that TA in fully dipped
into a tank of water to check if there are any cracks developed in the housing because if so the
bubbles will form which indicate damage in the housing.

- Flushing
In this test, TA is connected with the gear shifter and all the connections are done simulating an
actual gearbox and shifter stick setup as in real and it’s tested at various rpm. In this test TA is tested
to know if there are any irregularities while shifting or any noise while shifting.

- Ratio (load testing)

In this test a TA is connected to a motor which simulates the engine and provide power to
TA. Various loads at various gears and RPM are applied to check if the TA can withstand the
load and different combinations.

Gear No Gear Ratio Limit Set Speed Test Load Load Time
Input (RPM)
R +0.3/-0.3 1500 40 4
1 +0.3/-0.3 2000 40 4
2 +0.3/-0.3 2500 40 4
3 +0.3/-0.3 2500 40 4
4 +0.3/-0.3 2500 60 4
5 +0.2/-0.2 2500 60 4
6 +0.3/-0.3 2500 60 4

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Soft Shop Process -
 Shaping - Shaping machine is a machine designed for giving desired shapes to the
surfaces that may be horizontal, vertical, and flat. A shaping tool is used to cut in curves,
different angles, and many other shapes. The cutting tool is used to give the shape to
the hard surface of metal or wood by removing the excess material.

 Chamfering - Chamfering is making a small cut, usually at a 45-degree angle, to remove

a 90-degree edge. A chamfer is often specifically used to refer to a bevelled edge
connecting two surfaces. Milling cutters are used to cut the chamfers on the contour of
the teeth. The hard metal tools are pre-loaded and pressed onto the faces of the
workpiece at a defined angle.

 Hobbing - Hobbing is a machining process for gear cutting, cutting splines, and cutting
sprockets on a hobbing machine, which is a special type of milling machine. The teeth or
splines of the gear are progressively cut into the material (a flat, cylindrical piece of
metal) by a series of cuts made by a cutting tool called a hob.

 Deburring- Deburring is the process of removing the small imperfections known as burrs
from machined metal products. Machining processes shape a piece of metal in different
ways. After machining or welding, deburring removes these imperfections to provide a
smooth, reliable metal part.

 Shaving- Gear shaving is a finishing operation that removes small amounts of metal
from the flanks of gear teeth. Shaving improves the finish on tooth surfaces and can
eliminate tooth end load concentration, reduce gear noise, and increase load carrying
capacity.

 Rolling - Gear rolling is a production method where the gear can be formed from a blank
into final shape by using large plastic deformations. Therefore, no material will be
removed from the blank as in cutting based methods of gear production.

 Grooving - Grooving is a type of specific turning operation that cut grooves or forms a
narrow cavity of a certain depth on external, internal surfaces, cylinder, cone, or a face
of the part (face grooving or trepanning).

Page | 38
TA Shop Process Flow

Page | 39
 Hard Shop

Bore Grinding

Face Turning

Profile Grinding &

Honing

Quality Check

Bore Grinding - Grinding is used to finish workpieces that must show high surface quality (e.g.,
low surface roughness) and high accuracy of shape and dimension.

Face Turning – In face turning, the tool is fed radially towards the centre, at the end of the
workpiece. The radial cutting forces are high, which may generate deflection on the
component and may sometimes also cause vibration

• To provide a true
• flat surface
• square with the axis of the workpieces.

Profile Grinding – Grinding is the process of removing metal by the application of abrasives
which are bonded to form a rotating wheel. When the moving abrasive particles contact the
workpiece, they act as tiny cutting tools, each particle cutting a tiny chip from the workpiece.
Gear grinding is a hard finishing method for gears, using tools with a specific geometrical
profile. It is divided into two main groups: generating grinding and profile grinding, relating to
the manufacturing of the tooth flank.

Honing - Gear honing is characterized by leaving fine grinding marks due to grinding at an angle.
Grinding uses a gear honing wheel in the shape of an internal-tooth gear that meshes with the
workpiece to grind the tooth surface.

Page | 40
 Heat Treatment

Surface Hardening Process

Material – 16MnCr5

Diffusion increases the hardness of steels. Prewashing Carburisation is a heat treatment process
In diffusion hardening, diffusion occurs in which iron or steel absorbs carbon while
between a steel with a low carbon the metal is heated in the presence of a
content and a carbon-rich environment to Preheating carbon-bearing material, such as charcoal
increase the carbon content of the or carbon monoxide.
steel and ultimately harden the
workpiece. Carburizing

Diffusion
Forging methods refines grain structure,
In quenching the material is heated up to Forging develops inherent strength giving
suitable temperatures and then quenched characteristics, improves physical
in oil to fully harden, varying on the kind properties and produces structural
Quenching uniformity free from hidden internal
of steel being worked on. Items that go
defects.
through this are then aged, tempered or
stress relieved to achieve the desired Post Washing
stability.

Tempering
Tempering is used to achieve greater
toughness by decreasing the hardness of
the alloy. The reduction in hardness is
Quality Testing
usually accompanied by an increase in
ductility, thereby decreasing the brittleness
of the metal.

Quality Testing –

• The Rockwell hardness test is used for macro hardness tests, which are generally
defined as tests that use indentation loads below or equal to 1 kgf.
• Brinell hardness is determined by forcing a hardened steel or carbide ball of known
diameter under a known load into a surface and measuring the diameter of the
indentation with a microscope.

Page | 41
Page | 42
 Quality Analysis of Outsourced Parts.

Quality on which customer delight and satisfaction depends, Quality which is at core of any
manufacturing system, there are various parts that are been outsourced in TA shop from various
suppliers and in different conditions (Blanks, Semifinished, Fully Finished). Quality Checking of
various CTQ factors depend on product to product and the condition they are in.

Parts that are been outsourced in Transaxle Department-

1) Gears
a) Input Shaft Gears
b) Layshaft Gears
2) Shafts
a) Input Shaft
b) Layshaft
3) Housing
a) Front
b) Rear
4) GFD
5) Gear Shifter
a) Aluminum Assembled Gear Shifter
b) Welded Gear Shifter
6) Piston Cooling Nozzle*
7) Oil Pump*
8) Oil Pressure Sensor*

Page | 43
Gear quality
Gear quality standards are generally indicated in terms on DIN which is standard for all gear
quality.
DIN determines the spam size and geometric accuracy of any gear.

• Gears

Layshaft Gears –

Layshaft gears are the once which are externally mounted on the shaft, gears are made
from the blanks and later at the assembly they are mounted on layshaft.
All gears from 1st to Reverse are mounted on the layshaft, checking procedure of all the
gears are same but some gears are checked after hobbing, and some are checked at fully
finished condition depending upon the inward condition.

CTQ parameters –

• Runout - Checked on roll tester, in this gear is mounted on a mandril and then gear
in mounted on that mandrill and the plunger gauge shows the deviation once the
gear is rotated.
(for e.g. – 4th GLS is mounted on 30 mm mandril and allowable limit for the runout is
0.035 mm

Page | 44
 • Span- The span measurement is widely accepted as an accurate method for
measuring gear tooth thickness. Span measures the distance between the tooths
which helps us determine the tooth thickness.

Input Shaft Gears –

Input shaft gears are mostly machined on the shaft itself; they are not attached separately
like the layshaft gears. Only 5th and sometime 3rd and 4th gears are attached separately.The
testing parameter of these gears are same as that of the Layshaft gears.

Page | 45
Parameters checked on Hoffer
These parameters and procedures are common for both input and layshaft gears-
Flank - The mating surface of a gear tooth
measured between the pitch circle and the base
circle.

This is the report which the Hoffer generates after evaluating, and it creates the profile of
the gear of both left and right-side flank.

Image Source – (Google/Gear Inspection & chart

Interpretation by Robert H Moderow, ITW Illitron) Lead - Lead is the
axial advance of a helix gear tooth during one complete turn (360°),
that is, the Lead is the axial travel (length along the axle) for one
single complete helical revolution about the pitch diameter of the gear.

Page | 46
Image Source – (Google/Gear Inspection & chart Interpretation by Robert H Moderow, ITW Illitron)

Page | 47
Tooth Spacing - The distance between adjacent teeth measured on the pitch circle.
The hoffler shows the tooth to tooth distance in this type of graph format which helps us understand
the deviatiation in whole values.

Image Source – (Google/Gear Inspection & chart Interpretation by Robert H Moderow, ITW Illitron)

Page | 48
Image Source – (Google/Gear Inspection & chart Interpretation by Robert H Moderow, ITW Illitron)

Index Fp- Index Total cumulative pitch deviation Fp is the algebraic difference between the
maximum and minimum index values for a specified flank or the total amplitude of the index
deviation plot

As same as the tooth spacing Hoffer also creates a bar chart for the index which help us
determine that the total cumulative index is within the allowable tolerance limits.

Image Source – (Google/Gear Inspection & chart Interpretation by Robert H Moderow, ITW Illitron)

Input Shafts and layshafts have the same quality checking methods because some gears are
mounted on the shafts and are not externally fitted.
All the Hoffer CTQ like runout, index, tooth spacing, lead & profile are same for GFD and
shafts the only difference is that they have different standard and tolerance limits, and for
the layshaft we only measure these values at the single synchronous gear that there on
layshaft.

Page | 49
Housing

For checking a part like housing which consist of

over 300 different dimensional parameter there
are various methods that are been used.

For a part of this size first quality parameter is to

visually check for any damage, dents, cracks on the any of the edges and surface.

Sr.no. Parameter Method of checking

1 Hole Size Using PPG, TPG for threaded holes
2 Shaft Holes Using Vernier, Bore Gauge
3 Depth Depth Gauge
4
Surface Roughness Surface roughness tester
5
6 Fillet Radius Gauge
7 Flatness Filler Gauge, CMM
Thickness Micrometer

Other Complex Dimensions which are either very small in size or are hard to measure with any
instruments are measured over Coordinate measuring machine (CMM)

Image Source – google/Housing Engineering Drawing side view

Page | 50
Gear Shifter
 Aluminum Assembled Gear Shifter

Gear Shifters are the part which are fitted

over the gears which helps in changing the
gear as per the input received.

The Sifter Assembly consists of 3parts the

• Fork (which surrounds the gear)

• Shaft
• Dock (which is at the other end of shaft)

SR.NO PARAMETER EQUIPMENT

Page | 51
 SHIFTER FORK
1 Half Circle diameter Fixture
2 Distance form shaft hole center to shifter pad Fixture
3 Fork to shaft attachment slot hole Fixture
4 Distance between two shifter pads Fixture
SHAFT
5 Shaft Diameter Verner
6 Straightness Straightness Fixture
DOCK
7 Shaft Hole ID Fixture/Vernier
8 Dock Slot Opening Fixture (Go No-go Pin)
9 Dock Face Alignment Fixture
10 Symmetry (position) Fixture
11 Guiding hole Diameter Fixture/vernier

 Welded Fork Assembly

In welded fork assembly all the components are attached, there is no need to separately attach
them. Welded forks are economical as compared to aluminum assembled fork and it also have
less chances of wear as no of assembled component is reduced

SR.NO PARAMETER EQUIPMENT

1 Distance Dock to fork Fixture
2 Distance shaft end to fork Fixture
3 Distance Dock to ref pin Fixture
4 Angle Fork pad face to dock inner face Fixture
5 Dock Surface Flatness Fixture
6 Straightness of shaft Straightness Fixture
7 Twist between pads Using Height gauge with plunger dial
8 Perpendicularity of pads wrt shaft axis Perpendicularity Fixture

Page | 52
  Piston Cooling Nozzle
Piston cooling nozzles/jets play several crucial
roles in the power cylinder of an internal
combustion engine. Primarily, they help with
the thermal management of the piston and
provide lubrication to the cylinder liner and
the piston's wrist pin.
Image Source – google/piston cooling nozzle

PCN testing

A test rig is used to Piston cooling nozzle, the rig simulated an actual engine environment
and flow rate through the PCN is measured at various pressure, & cracking pressure is also
noted.
Pressure Test Cycle Duration
Cracking Pressure -
3 Bar 60 sec
4.5 Bar 30 sec

 Oil Pump
The oil pump in an internal combustion engine part that circulates engine oil under pressure to the
rotating bearings, the sliding pistons, and the camshaft of the engine. This lubricates the bearings,
allows the use of higher-capacity fluid bearings, and assists in cooling the engine.

There are 5 oil channels to which oil pump supplies oil: -

• Five crank-shaft bearings

• Four piston cooling jets • Middle distribution gear.
• At the exit of the crank-shaft bearings, through internal ducts, the oil lubricates the 4 camshaft
bearings.
• The last crankshaft bearing, lubricates a plain shaft bearing.

Page | 53
Oil Pump is checked to ensure its properly working and its within in specified limits for flow rate,
pressure as LOP (low oil pressure) pumps can be a problem when attached to a engine as it would
not lubricate the engine properly and insufficient cooling or lubrication can wear out the engines life.

So, to ensure oil pump is properly working it’s been tested under various RPM to check flow rate –

Sr.no RPM Flow Rate Specifications

1 800 8 to 11 LPM
2 1700 20 to 25 LPM
3 400 45 to 50 LPM
4 Relief Pressure 6.75 ± 0.5 Bar

• Part inspection & Development

During the overall operations, parts need to be changed or replaced or either they
need minor modifications to meet certain requirement or standards or to fit in the
production requirement or if an additional supplier is added. Every time parts undergo
certain changes VQA checks the part for various parameters to assure that part is of
good quality and can meet the standards as required.

Development Process –

Page | 54
 Component
Modification

Part Offered to VQA

by concerned AQ/CQ

Part Validation
(Visual checking of
part against the drw)

Part Checking by concentered Sub

dept according to drw parameters

1st Principle CMM Meteorology Metallurgy

Final Report
If Accepted If Rejected

Testing at line Scrap/Return

to vendor

Page | 55
 • Instrument/Machines Used for Inspection

Sr. no Parameter Instrument

1 Height Vernier, Height Gauge

2 ID/OD Vernier, Micrometer, Comparator, Bore Gauge

3 Angle Bevel Protector
4 Chamfer Microscope
5 Surface Roughness Surface Roughness Tester

6 Flatness CMM, Filler Gauge

7 Perpendicular CMM

8 Runout Dial, CMM

9 Radius Radius Gauge, CMM
10 Tapping TPG, PPG
11 Straightness Dial, CMM

12 Leak Test Leak testing machine

13 Millipore Millipore test kit, Particle size analyser

Page | 56
 • Surface Roughness Tester
Roughness tester is used to test the machining finish or any machined surface. Surface
roughness standard lies between N1-N12 based on the size and machining operation.

SRT gives the output in terms of Ra & Rz values which determines the amount of uniformity
or irregularity in machining operation.

Page | 57
• Millipore Testing
Millipore testing is used to determine the cleanliness of any component which would
carry fuel or any other critical fluid. It is used to check cleanliness in hoses or casted
components.

Page | 58
Quality Tools used at Shop Floors

Poka-yoke

Poka-yoke is a lean manufacturing tool that refers to “mistake-proofing” or “error-proofing”

a process. There is multiple such mistake proofing done at the shop floor to ensure safety &
seamless flow of the operations. Because one single mistake can lead to a bigger cost at
shop floor, it may lead to total production stoppage.

Poka-yoke at machining
All the machines are equipped
with such feature which will
ensure that no human error
should occur or even if they
occur that should not affect
the whole process.

EG – In any punching machine there are 2 swich given to start any operation, just to ensure
that workers hands are not around the punching area and its safe.

EG- In Layshaft fitting machine there is a sequence which workers follow first they put
bearing inner race and then oil bush so to ensure that they are going with a proper flow
there are various optical sensors and cameras which ensure that previous operation is
completed otherwise machine won’t let the worker to initiate further operations.

Page | 59
Poka-yoke of Poka-yoke

In every shift they ensure that the poka-yoke any machine is working fine they do a sample
test by putting wrong sequence or wrong product to ensure how does the machine respond
to it, & they maintain a daily poka-yoke check sheet of poka-yoke process

Page | 60