Industrial Training Presentation

on
Manufacturing of Engine and Transmission
Components
at

History of Yamaha Motors India

1955
Genichi Kawakami founded Yamaha Motors. YA-1 was the first
bike manufactured in 125cc.

Genichi Kawakami

The YA-1

1965
Manufacturing activities shifted to the present building of
Faridabad Plant.

 1984
Setup Plant in Surajpur near delhi jointly with Escorts.

1985
Started manufacturing of RX-100 cc Motorcycle with technical
collaboration with Yamaha Motors Company of Japan, at
Surajpur plant.

2009
Assembly lines at Surajpur were installed and spread over an
area of 36,000 sq. mts. It has the capacity to produce 1 million
motorcycles and scooters annually.

 It is under Construction
Installed with all machining, casting, welding
and assembly lines.
Established in 1984
Engine, Transmission and Vehicle Assembly is done here
Welding of Frames.

Established in 1965 and upgraded in 2008

Consists of Machining, Casting and Paint shop

Chennai
Plant

Surajpur
Plant

Faridabad
Plant

In India, Yamaha has three Plants

INDIA YAMAHA MOTORS

Faridaba
d Plant

Machine
Shop

Engine
Compone
nts

Casting
Shop

Transmis
sion
Compone
nts

Engine
Compone
nts

Paint
Shop

Engine
Compone
nts

Transmis
sion
Compone
nts

Transmis
sion
Compone
nts

Machine shop
Faridabad Plant has In-house
facility for Machining, Casting,
Paint, Hardening and
Electroplating.
Its Machine shop is well
equipped with latest CNC and
VMC Machines making it
capable of Producing every
components.
It Produces various Components
like Head & Body Cylinder,
Gears, Crank, Camshaft, Axles,
Crankcase.

Body Cylinder

Head cylinder

Engine
Assembly
Components

Crank &
Connecting
Rod

Cam Shaft

Head Cylinder
Cylinder Block is made into two parts :1. Head Cylinder
2. Body Cylinder
Head cylinder plays a important role in combustion as it contains
the combustion chamber and guide mechanism for the fuel to be
entered for combustion.
It also contains :1. Inlet and Outlet valves
2. Cam and rocker assembly
3. Spark Plug

Timing Chain Slot

Inlet Valve

Cam shaft and its

Bearing

Outlet Valve

Spark plug
Opening

Fig. Head Cylinder

BODY CYLINDER
Body Cylinder is a part of the Cylinder Block.
It mainly encloses the cylinder in which piston moves and
provision
for liquid cooling.
Passage for Coolant

Tapping for STUDS

Cylinder

Fig. Body Cylinder

Its Functions : To ensure proper functioning of the piston inside the cylinder.
It also dissipate heat to the atmosphere preventing the heating of
the engine
It also subjected to various pressure that has been developed due to
the combustion of the fuel inside the cylinder.

Materials Used :Yamaha uses two materials for body cylinder :1. Aluminium (have steel liner)
2. DiASil (no need of steel liner)

What is DiASil Cylinder ?

Problem Encountered :The cylinder wall is exposed to constant friction from the piston,
a steel sleeve is inserted in the cylinder to achieve high abrasion
resistance. If the sleeve is eliminated in order to improve heat
dissipation, the aluminum cylinder by itself doesnt have the
strength to provide sufficient abrasion resistance.
Solution :To solve this problem DiASil Cylinder adds a silicon content of
20% (twice that of regular aluminum) to the aluminum alloy to
achieve the required hardness to resist abrasion.

Benefits of DiASil Cylinder : It is lighter and has better cooling performance.

No need of a steel sleeve because it is made of abrasion-resistant
aluminum alloy.
Has a heat dissipation rate that is three times better than steel,
which means great cooling performance

Manufacturing Process on Body

Cylinder

Facing of both sides

Drilling
Reaming of drills
Face milling and dowel drilling
Inspection of Dimensions (done with the help of air guages)
Honning
Leakage Check

Honning
Honing improves cylinder performance by
producing more uniform and controlled
bore geometry, size and surface finish
It is also used to make hatches inside cylinder
It is done so that the lubricating oil stucks
in the hatches, thus improving the
lubrication.
Hatching angle lies in 15-30 .

Air Gauges
Air gaging is a non-contact means of precise comparative
dimensional measurement
It is ideal for measuring dimensions with tolerances smaller than .
005", and when gaging tight tolerances, a resolution as small as .
000002" can be achieved.

Working
Air gaging relies on the laws of
physics which state that flow and
pressure are directly proportionate
to clearance and they react inversely
to each other.

 The regulated air flows through the restriction a needle valve,

jeweled orifice, etc. and then through the nozzle. When the nozzle
is open to the atmosphere, there is maximum flow through it and
there is a minimum of pressure called back-pressure between
the restriction and the nozzle.
As an obstruction is brought increasingly close to the front of the
nozzle, air flow from the nozzle
diminishes and back pressure
builds. When the nozzle is
completely obstructed, air flow
is zero, and back-pressure reaches
the pressure of the regulated
air supply.

CRANK
It is used to convert the reciprocating motion of the piston into the
rotatory motion.
It transmits power that is obtained after the combustion of fuel in
the cylinder to the transmission and dynamo.
It is used in balancing of engines to reduce vibrations.
Hole for Crank
pin

Key way
Crank to
transmission

Dynamo Side Crank

CONNECTING ROD

It is used to connect the piston and the crankshaft and transmit

the power from the piston to the crank. It has two ends :1. Small End
2. Big End
Small End is Connected to the piston and Big End is
connected to the crankshaft.

CAM
Cam is a mechanical component which is used to convert
rotatary motion into reciprocating or oscillating motion.
In engines, it is used to actuate the inlet and outlet valves
Bearing
Timing
Sprocket
CAM Lobes

Axle Main

Gears

Transmission
Assembly

Dog Clutch

Axle Drive

GEAR
Gears are toothed wheels which transmit power and motion from
one shaft to another by means of successive engagement of teeth.
Classification of gears used in gear box :1. Spur Gears
2. Helical Gears

AXLES
Axles are used to provide support to the gear and to
transmit power to the gears from the engine.
Sometimes, on axles teeths have been cut in order to
mesh directly with the pinion or gear.
There are two axles used in gear box :1. Primary Drive
2. Axle Drive

Manufacturing of Gears
and Axles

Turning
Hobbing
Deburring
Shaving
Centre drill
Outer Diameter Grinding
Induction Tempering
Keyway Cutting

 After these processes, further processes carried out which

includes :1. Induction Hardening of Gear and axles
used to increase the hardness of the surface of gears so that the
steel balls do not impinges inside the surface of the gear
Also used to increase the hardness of the splines cut on the gear
and axles.

2. Shot Blasting.

Shot Blasting
Shot Blasting is a surface treatment process using high velocity
steel abrasive.
The components placed on the rotary table are continuously passed
through the blasting zone. This guarantees a uniform blasting of the
surface.
In general shot blasting concentrates abrasive particles at high
speed (65-110 m/second) in a controlled manner at the material
thereby removing surface contaminates due to the abrasive impact.

 Shot blasting systems are comprised of 4 basic subsystems:

1. Abrasive delivery method:
a. By Compressed Air.
b. By Centrifugal turbines.
2. Abrasive recovery and cleaning.
3. Dust collection.
4. Blast Cabinet.

Shot blasting is commonly used for :

The cleaning of iron, steel, non-cast parts, forgings, etc.
Shot peening to alter mechanical properties (increasing resistance to
fatigue for springs, gears, etc.)
Mechanical cleaning of sheets, rods, coils, wire, etc.
Preparing surfaces to be painted, coated, etc.

Before Shot blasting

After Shot Blasting

Fig. Transmission Assembly

THANK YOU

Submitted To:
Mrs. PRATIBHA
KARWAL
Mr. AJAY SINGH
VERMA

Submitted By:
NITIN KUMAR
(1102940068)