93 INDUSTRIAL TRAINING

Industrial Training aims at exposing the students to field practices, size and scale of operations and work culture at practical sites. For this purpose, students at the end of fourth semester, are required to be sent for a period of 4 weeks at different work sites at the end of the 4th semester. The evaluation will be done in the fifth semester. Each student is supposed to study the material and technology used at site and prepares a detailed project report of the observation of processes seen by him/her. These students should be supervised and guided by respective subject teachers. Each teacher may guide a group of four to five students. The teacher along with field supervisors will conduct performance assessment of students. The components of evaluation will include the following. Punctuality and regularity Initiative in learning new things Relationship with workers Industrial training report 15% 15% 15% 55%

94 5.1 AUTO REPAIR, MAINTENANCE AND DRIVING PRACTICE I L T P Cr - - 12 6 RATIONALE Testing and trouble shooting of various electrical components and systems of automotive vehicle is an area where a diploma holder must have proficiency. He should be fully aware about the procedures of overhauling of engines, gearbox, and differential. He should be trained in using various controls while driving on road, in plains and hilly areas. That is why, this subject has been introduced. LIST OF PRACTICALS 1. 2 3. 4. 5. 6. 7. 8. 9. Testing of battery with hydrometer, high rate discharge tester, charging of batteries. Testing and setting of ignition timing with timing light, cam angle tester, and dwell angle tester. Testing and cleaning of spark plug. Diagnosing electronic ignition system, magneto ignition system. Colour codes and sketching of complete wiring circuits of an Indian automobile. Inside and outside inspection/checking of vehicle, checking of engine oil, horn, starter, coolant before starting of engine. Adjusting Clutch free play and cleaning clutch plate and assembly Setting brake pedal free play and carry out bleeding. Gear changing from low to high and high to low speed on the road.

10. Practice on general road safety, road and traffic signals and driving regulations. 11. Driving practice on road for steering control. 12. Starting of engine and warming up. 13. Overhauling of petrol engine. 14. Overhauling of gearbox. 15. Overhauling of differential. 16. Servicing of suspension system, leaf springs, independent suspension, coil spring, torsion bar, telescopic shock absorber. 17. Removal and fitting of wheels and tyres of a two wheeler and repairing of punctures 18. Cleaning, greasing, checking as per maintenance schedule of two wheelers 19 Cleaning, greasing, checking as per maintenance schedule for washing, wiping and polishing of jeep/car

20. Overhauling of diesel engine

95 RECOMMENDED BOOKS 1. 2. 3. 4. 5. Automobile Engineering by Kirpal Singh, Standard Publishers, Delhi Automobile Electrical and Electronic System by Tom Denton; Arnold, London, Automotive Electrical Equipment by P.L. Kohli. Automotive Electrical Equipment by William H. Crouse. Automobile Engineering by R.B. Gupta, Satya Parkashan, New Delhi

96 5.2 ELEMENTS OF DESIGN L T P Cr 4 - - 4 RATIONALE Understanding of basic principles of components like cylinder liner, piston, crank shaft, connecting rod, simple mechanisms are essential for diploma holders in Automobile Engineering, hence this subject. DETAILED CONTENTS

1.

Introduction -

(16 hrs)

Design consideration, design procedure Basic requirements, classification of design and principles of good economic design Standardization, interchangeability of automobile parts with reference to IS specifications Limits, fits and tolerances Materials selection and ergonomics Designing for strength (48 hrs)

2.

Designing of Auto Parts i) Design of : ii) Design of : ii) Cylinder liners Flywheel Bearings Joints and pulleys Gears Shaft under torsion Shaft under combined bending and torsion Keys and flanged coupling

Design of : Piston and piston Assembly Connecting rod Crank Shaft Cam shaft

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INSTRUCTIONAL STRATEGY Teacher should lay emphasis on conceptual understanding and design aspects of various parts/components. Various models should be demonstrated in the class to explain mechanism RECOMMENDED BOOKS 1. A Text Book of Machine Design by RS Khurmi & JKGupta, Eurasia Publishing House, Pvt. Ltd.., New Delhi Theory of Machines by PL Ballaney, Khanna Publishers, New Delhi Theory of Machines by DR Malhotra & HC Gupta, Satya Prakashan, Delhi

2 3

SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 Total Time allotted (Hrs) 16 48 64 Marks Allotted (%) 25 75 100

98 5.3 GARAGE EQUIPMENT L T P Cr 4 - - 4 RATIONALE Management of garages forms an important function of automobile technicians. To perform such functions, knowledge of service station equipment, tuning equipment, engine repair tools, electrical repair equipment and reconditioning and fabrication of equipment is very essential. Hence the subject. DETAILED CONTENTS 1. General Tools Specifications and applications of Screw drivers Spanners and wrenches Pliers Hammers Chisels Files Hacksaw Tools for tubes flaring Taps and dies Reamers Soldering tools Measuring tools- vernier calipers, inside and outside micrometers Feeler gauge Tommy bar Nut runner Cleaning tools Nipple forming tools Torsion bar/torque wrench 2. General Equipment Specifications and applications of Drilling machine (portable) along with set of drills Bench grinder Air compressor Hydraulic and electric hoists High pressure washing equipment Oil sprayers Grease Guns-manual and bucket type, pneumatic Tyre inflation gauge (Manual and Digital type automatic) Tyre Changer (Manual and Automatic) (12 hrs) (6 hrs)

99 Creepers Electric and gas welding equipment Fire extinguisher First aid box Chain pulley block Lubrication equipment 3. Tuning and Testing Equipment Specifications and applications of Vacuum Gauge Compression Gauge (Pressure Gauge) Distributor Tester cam (dwell) angle tester, r.p.m. tester. Battery Tester Spark plug cleaner and tester Ignition timing light Fuel injector tester Fuel consumption tester 4. Engine Repair Tools/Measuring and Testing Equipment Specifications and applications of Torque wrench, pneumatic wrench Piston ring compressor Valve lifter and valve spring tester Piston ring files, groove cleaner Scrappers Piston ring remover Cylinder Dial gauge Smokemeter Exhaust gas analyzer Engine Analyser/Scanner Engine work stand Gear box work stand Part degreasing tank Thermostat testing fixture Compression gauge for diesel engine 5. Electrical Repair Equipment Specifications and uses of Electrical Test Bench Battery Charger (6 hrs) (12 hrs) (6 hrs)

100

Head Lights Beam Aligner and Tester (Electronic and Digital type) Growler Inspection lamp 6. Reconditioning/Testing Equipment for Chassis and Body (6 hrs)

Use of Brake Efficiency Tester (Chassis Dynamometer) or brake testing equipment Clutch Fixtures and Brake Line Rivetters, pop riveting gun Crane and Chain Pulley Block Jacks mechanical, hydraulic, trolley type Paint chamber Paint Spray Gun Paint Drying Equipment Tools for tyres, automatic tyre remover Trolleys Axle/chassis stands Steering work stands Jib crane Spring tester Frame strengthening equipment Chassis alignment equipment Steering geometry and alignment gauges Computerized wheel balancer static and dynamic Computerized wheel alignment equipment

7.

Engine Reconditioning and Testing Equipment Specifications and use of Cylinder Boring Machine and Honing Machine Crankshaft Machine and Camshaft Grinding Machine Connecting Rod Aligner Line Boring Machine and Arbor Press Nozzle Grinding and Lapping Machine Fuel Injection Pump Calibrating Machine Valve Refacer, Valve Seat Cutting and Grinding Radiator Tester Cylinder head leakage testing fixture Cylinder chamfering device Fuel injector tester Nozzle cleaning equipment

(16 hrs)

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RECOMMENDED BOOKS 1. 2. 3. Automotive Mechanics by WH Crouse and Donald Anglin; Tata Mc Graw Hill Publishing Co. Ltd., Delhi. Auto Mechanics Fundamentals by MW Stockel, Goodheart Wilcox Publishers. Automobile Engineering Vol. I and II by Dr. Kirpal Singh; Standard Publishers, Delhi.

SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 7 Total Time allotted (Hrs) 6 12 6 12 6 6 16 64 Marks Allotted (%) 10 20 10 20 10 10 20 100

102 5.4 AUTOMOTIVE EMISSION CONTROL L T 4 RATIONALE Pollution is a matter of concern for all living things. A diploma holder in automobile engineering should have knowledge about sources of pollution, method of measuring emissions and managing pollution control. Hence this subject of automotive emission control has been added in the curriculum DETAILED CONTENTS 1. Engine Exhaust Pollutants 1.1 Exhaust gas constituents and analysis on board diagnosis and lamda concept. Ingredients responsible for environmental pollution Fuel air equivalence ratio and its effect on concentration of polluting elements Smog formation Greenhouse effects - role of CO2 emission Visible smoke EURO standards P Cr - 4

1.2

1.3 1.4 1.5 1.6 2.

Sources of Automotive Emission 2.1 2.2 2.3 Fuel and air Emission from fuel tank, carburettor, crank case, exhaust system Major factors influencing exhaust composition 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 Combustion temperature Spark timing or injection timing CO emission and air fuel ratio Mechanisms of HC formation in SI and CI engines Effect of cold climatic conditions on emission

3.

Emission Control 3.1 Emission control by Engine design measures 3.1.1 Setting the A/F ratio

103 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.2 Mixture formation Exhaust gas re-circulation Valve timing Compression ratio Combustion chamber shape Ignition system

Emission control by exhaust gas treatment 3.2.1 3.2.2 3.2.3 Air injection into exhaust gases Thermal after-burning Catalytic after-burning Oxidation type catalytic converter Reduction type catalytic converter Dual-bed catalytic converter Three-way or selective catalytic converter Particulate traps. Regeneration of diesel filters

3.2.4 3.3 3.4 3.5

Positive crankcase ventilation Evaporative loss control Fuel modifications 3.5.1 3.5.2 Unleaded petrol Low, ultra low sulphur diesel

4.

Emission Measurement 4.1 4.2 4.3 4.4 Measurement on vehicles using chassis dynamometer Measurement on engine using engine dynamometer Exhaust gas analyzer Smoke meter for measuring visible smoke in diesel engine 4.4.1 4.4.2 4.4.3 4.5 BOSCH Method or filter paper method Light absorption method by measuring opacity Steady state measurement of smoke

Blow-by meter 4.5.1 4.5.2 Significance of engine blow-by Blow-by meters and limits to blow-by quantities

104 5. New Technologies for Emission Control 5.1 5.2 5.3 5.4 6. Gasoline injection system, MPFI system Variable valve timing and lift Turbo charging Common rail system for diesel engines

Alternative fuels for Automobiles 6.1 6.2 6.3 6.4 6.5 6.6 6.7 CNG, LPG, LNG Alcohol Biodiesel Electric vehicles Hybrid vehicles Fuel cell Technology Solar energy

INSTRUCTIONAL STRATEGY While imparting instructions, the emphasis should be on sources of automotive emission, principles related to measuring emission and controlling it. Visits to industry should be organized to demonstrate equipment for emission measurement RECOMMENDED BOOKS 1. 2. 3. 4. Automotive Emission Control by WH Crouse; McGraw Hill Publishing Company Ltd., New Delhi Automobile Engineering by Anil Chikara; Satya Parkashan, New Delhi Automobile Engineering by GBS Narang, CBS Publishers and Distributors Automobile Engineering by Dr. KM Gupta, Umesh Publishers, Delhi SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 Total Time allotted (Hrs) 8 8 16 16 10 6 64 Marks Allotted (%) 12 12 25 25 16 10 100

105 5.5 MECHANICS OF VEHICLES L T P Cr 4 - - 4 RATIONALE Understand the basic mechanism and motions, power transmission, vehicle braking, vibrations and balancing are essential for diploma holder in automobile Engineering and hence this subject. DETAILED CONTENTS 1. Simple Mechanism 2. (8 hrs)

Definition of link, kinematic pair, kinematic chain, mechanism, inversion and machines Simple examples of mechanism with lower pairs, four bar chain, slider crank chain, double slider crank chain, higher pairs (10 hrs)

Motion of Various Types Displacement, velocity and acceleration of piston.

Angular velocity and angular acceleration of connecting rod. Calculations of piston effort and crank effort at different angles Turning moment diagrams with reference to internal combustion engines Fly wheel - its types, weight and moment of inertia Fluctuation of energy for fly wheel Speed control by governor (12 hrs)

3.

Power Transmission Flat belt, V belt and chain drives

Ratio of tension on two sides of the belt with and without centrifugal tension Horse power transmitted and condition for maximum horsepower transmitted Velocity ratios transmitted by Belts; Simple, compound and epicyclic gear box. (12 hrs)

4.

Vehicle in Motion Air resistance, grade resistance, and rolling resistance

Tractive effort, traction, Inertia load, Draw bar pull and power required to propel a vehicle.

106 5. Calculations of acceleration and tractive effort required in case of four wheel drive, rear wheel drive and four wheel drive. Centrifugal force and its effect on vehicle stability on banked and unbanked road Aerodynamics of vehicle (10 hrs)

Vehicle Braking Braking friction and limits of braking.

Retardation and Braking force, calculations in case of front wheel, rear wheel and all wheel braking. Weight transfer during braking and its effect Braking efficiency, stopping distance and stopping time (6 hrs)

6.

Balancing Concepts of static and dynamic balancing

7.

Vibrations
-

(6 hrs)

Causes of vibration in rotating bodies, damping of vibrations.

INSTRUCTIONAL STRATEGY Teacher should lay emphasis on conceptual understanding of working of various mechanisms used in the automobiles and design aspects of various parts/components. Teacher should demonstrate various models in the class to explain various mechanisms. Simple problems and tutorial exercises should be provided so that the students can comprehend the subject. RECOMMENDED BOOKS 1. 2. Theory of Ground Vehicles by J.Y. Wong, John Willey & Sons, New Delhi Mechanics of Road Vehicles by W Stead, Kefe Books Ltd. London SUGGESTED DISTRIBUTION OF MARKS
Topic No. 1 2 3 4 5 6 7 Total Time allotted (Hrs) 8 10 12 12 10 6 6 64 Marks Allotted (%) 12 16 18 18 16 10 10 100

107 5.6 MANUFACTURING TECHNOLOGY - II L T P Cr 3 - 3 5 RATIONALE Knowledge in various machining operations viz. drilling, boring, milling, planning and grinding processes, finishing operations, gear production, CNC machining, bending forming and welding processes is very essential for the diploma holders. Hence this subject. DETAILED CONTENTS 1. Drilling and Boring Introduction, Types of drills, types of drilling machines i.e. portable, bench type, piller and radial, drilling speeds and feeds, drill chucks and other accessories (jigs etc.) used in drilling, reaming, introduction to boring, specification and types of boring machines horizontal and vertical, boring bar and boring heads 2. Machining Processes Milling Types of milling machines and their operations, speeds and feeds, indexing (simple and compound), types of milling cutters Planing machines and their operation Grinding cylindrical, centreless and surface grinding machines, crank shaft grinder, types of grinding wheels, specifications, grades and their selection, balancing of grinding wheels and their storage 3. Finishing Operations Surface finish concept and checking Lapping, honing, super finishing operations and their applications, types of abrasives used and their selection 4. Gear Production Gear cutting and gear shaving machines, gear cutters and coolants 5. CNC Machines Introduction to CNC control systems, advantages 6. Bending and Forming Description of press brakes, bending dies, forming machines (4 hrs) (4 hrs) (4 hrs) (4 hrs) (12 hrs) (8 hrs)

108 7. Welding Introduction, types of welding (gauge welding, arc welding, resistance welding), butt welding, flash, projection, seam and spot welding, TIG welding. Selection of electrodes, filter metals, types of welding defects and their remedies, soldering and brazing processes and applications Special welding processes for stainless steel and aluminum Automation in welding 8. Types of Coolants and Lubricants for various machining processes (2 hrs) (10 hrs)

LIST OF PRACTICALS 1. Introduction to drilling and boring machines, an exercise of simple drilling and boring operation, selection of speeds and feeds, use of jigs and fixtures and coolant. 2. Simple exercises on shaper 3. Practice on horizontal and vertical milling machines, work holding devices and types of milling cutters 4. Practice on cylindrical and centreless grinding machine, selection, dressing and storage of grinding machines. Balancing of grinding wheels. Use of lubricants 5. Practice on honing machines with selection of honing sticks, honing and finish pattern in the bore. Bore geometry measurement 6. Observe working of CNC machines including setting of cutting parameters and dimensions and loading of tools, repeatability of operation and adjustment for wear allowances 7. Visit to industry (sheet metal shops) to observe bending and forming operation and use of dies 8. Use of appropriate coolant and lubricants for all machining operation in the workshop and during Industrial visits. RECOMMENDED BOOKS 1. 2. Workshop Technology by BS Raghuwanshi, Dhanpat Rai & Sons, Delhi. Workshop Technology Vol. I, II & III by Chapman, Standard Publishers Distributors, New Delhi. 3. Workshop Practice by RK Singhal, SK Kataria & Sons, New Delhi.

109

4. 5.

Production Technology by HMT, Tata McGraw Hill, New Delhi. Elements of Workshop Technology by SK Chaudhary & Hazra, Asia Publishing House.

6.

Workshop Technology by Manchanda, H. Tata Publications, Delhi SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 7 8 Total Time allotted (Hrs) 8 12 4 4 4 4 10 2 48 Marks Allotted (%) 18 25 8 8 8 8 20 5 100