Industrial Training Presentation on

Manufacturing of Engine and Transmission Componentsat

Introduction

History of Yamaha Motors India • 1955 ‘Genichi Kawakami’ founded Yamaha Motors. YA-1 was the first bike manufactured in 125cc.• 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.

INDIA YAMAHA MOTORS In India, Yamaha has three Plants

Faridabad Plant •Established in 1965 and upgraded in 2008

•Consists of Machining, Casting and Paint shop

Surajpur Plant

•Established in 1984• Engine, Transmission and Vehicle Assembly is done here.•Welding of Frames.

Chennai Plant

•It is under Construction•Installed with all machining, casting, welding and assembly

lines.

Faridabad Plant

Machine Shop

Engine Components

Transmission Components

Casting Shop

Engine Components

Transmission Components

Paint Shop

Engine Components

Transmission Components

Machine shop

• Faridabad Plant has In-house facility for Machining, Casting, Paint, Hardening and Electroplating.

• It’s 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.

Various Common Operations Performed on the components

1. Milling2. Facing3. Turning4. Drilling5. Chamfering6. Boring7. Counter Boring8. Tapping9. Reaming10. Honing11. Hobbing12. Shaving13. Shot Blasting

Head cylinder Body Cylinder

Cam Shaft Crank & Connecting Rod

Engine Assembly

Components

Head Cylinder•Head-Cylinder is a part of the Cylinder Block. Cylinder Block is made into two parts :-1. Head Cylinder2. 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 valves2. Cam and rocker assembly3. Spark Plug

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.

Fig. Body Cylinder

It’s Functions :-• To ensure and 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. DiASil (no need of steel liner)2. Aluminium (have steel liner)

Why 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 doesn’t 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

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.

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

Gears

Axle MainA

xle Drive

Dog Clutch

Transmission

Assembly

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

Images of gear blank and after hobbing from solidworks

• After these processes, further processes carried out which includes :-

1. Induction Hardening of Gear and axles. 2. Shot Blasting.