P.E.

S COLLEGE OF ENGINEERING, MANDYA

(AN AUTONOMUS INSTITUTION AFFILIATED TO VTU, BELGAUM)

INTERNSHIP REPORT
SAN ENGINEERING AND LOCOMOTIVE CO & Ltd.
Mysore
FROM JAN - FEB 2019

Submitted By
ABDUL ZUBAIR (4PS16ME001)
MOHAMMED HASHIM (4PS16ME054)
MOHAMMED MAVIYA SHARIFF (4PS16ME055)
6th SEM
DEPARTMENT OF MECHANICAL ENGINEERING
P.E.S.C.E MANDYA

Under the guidance of

Mr. YASHWANTH KUMAR
Senior Engineer - Planning
SAN ENGINEERING AND LOCOMOTIVE
Mysore- 571186
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1) INTRODUCTION
COMPANY PROFILE
HISTORY:

SAN ENGINEERING AND LOCOMOTIVE, Mysore was established

in 1985 as a locomotive manufacturing company. Over the years, the
company has grown its product portfolio and aligned its offering to changing
market requirements. Today, SAN is a multi-product, multi-market
enterprise that provides solutions in all segments of industries.

SAN is built on a strong foundation of innovation and technological

excellence. Strategic partnerships to strengthen our in-house engineering
capabilities and market reach, continuous focus on research and
development, and a customer-centric approach have marked the company’s
journey in the design and manufacture of locomotives, power packs and
gear

VISION :

Whether it’s in the partnerships that we forge or the

products that we design, we take pride in building long-term relationships
with our customers and making long-lasting impact in their businesses.
SAN is today known for the reliability of its products, superior technology,
manufacturing capabilities and values that stem from our core belief of
making long-term investments and commitments.

DIESEL HYDRAULIC LOCOMOTIVE :

Diesel hydraulic shunting locomotives are engineered to
last. Powered by either a CUMMINS or a CATERPILLAR engine with a
hydrodynamic transmission engineered by VOITH and built by SAN in India,
the locomotives are rugged, high on performance and low on downtimes.
What makes the SAN modular locomotive family different is its technology,
variety, performance potential, economy and eco-friendliness.

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SERVICES :
To satisfy the requirements of our customers, we consistently incorporate
new developments and new locomotive types in our portfolio. We do not see
ourselves solely as a supplier of diesel locomotives but we add value to the
customer

o in locomotive selection,
o Sizing and
o Maintenance

During these consultations, the focus is always on the efficiency of vehicle

usage. From a broad range of shunting locomotives, the customer chooses

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the vehicle that suits them the best in terms of performance, weight and
usage.

San is available to its customers with advice and assistance throughout the
life cycle of the locomotive. We help the customer choose the vehicle with the
aid of internally developed software and provide a comprehensive service
covering everything from maintenance and an efficient supply of parts to
complete vehicle retrofits.

Our engineering products team is available for sizing of cardan shafts, gears
and gear boxes for varied applications. With the latest engineering
softwares, our design team is capable of designing customized gear boxes for
varied applications.

Our Bangalore location has state of the art facilities for maintenance, repair
and  overhaul of transmissions and final drives of our diesel hydraulic
locomotives. Our Mysore facility can refurbish and repair gear boxes and
cardan shafts.

Power packs
SAN Specializes in providing power packs for a variety of applications .
These power packs are used in critical applications and are supplied to the
INDIAN RAILWAYS through integral couch factory and bharath movers Ltd.
SAN not only supplies the power pack but also helps the couch builder in
the integration process.
Application :

 OHE (Over head equipment inspection cars)

 SPART ( Self propelled accident relief trains)

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SERIES OF OPERATION IN PRODUCTION

Stress Releaving

Turning for Hobbing

Hobbing

Case Carburising

Case Layer Removal (CLR) Turning

Harning and Tempering

Finish Turning

Internal Grinding

Gear Grinding

Fitting

Inspection and Dispatch

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2) MATERIALS USED
EN09
1. EN09 Steel Grade
EN09 steel grade belongs to the standard of BS 970-1955, which is a
standard for wrought steel for mechanical and allied engineering
purpose. In BS 970 standards, there are some other common steel
grades, like EN19, EN24, EN36 etc. And the most equivalent is grade
080M40 steel in BS 970-1991.

2. EN09 Carbon Steel is Available in Following Shape:

We could supply EN8 steel in bright round bar in drawn/turned
condition or round hot rolled, hexagon, square, steel flats and plate.

DIFFERENCE BETWEEN EN09 AND EN19

Both EN9 and EN19 are steel grades in BS 970 standard. BS 970 is
one steel specification for wrought steel for mechanical and
allied engineering purposes. It specifies requirements for carbon and
carbon manganese, alloy, free-cutting and stainless steels normally
supplied in the bright cold finished condition. It is only applicable to
steels supplied in straight lengths.

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#2 EN9 vs EN19 Steel: EN9 is carbon steel, while EN19 is alloy steel

3) HEAT TREATMENT :
 Heat treatment is the heating and cooling of metals to change their physical
and mechanical properties, without letting it change its shape. Heat
treatment could be said to be a method for strengthening materials but
could also be used to alter some mechanical properties such as improving
formability, machining, etc. The most common application is metallurgical
but heat treatment can also be used in manufacture of glass, aluminum,
steel and many more materials. The process of heat treatment involves the
use of heating or cooling, usually to extreme temperatures to achieve the
wanted result. It is very important manufacturing processes that can not
only help manufacturing process but can also improve product, its
performance, and its characteristics in many ways.

Hardening
Hardening is the process of increasing the hardness of the material by
heating the material/component upto its recrystallisation temperature and
cooling at different cooling rates

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Tempering
Tempering involves heating steel that has been quenched and hardened for
an adequate period of time so that the metal can be equilibrated. The
hardness and strength obtained depend upon the temperature at which
tempering is carried out. Higher temperatures will result into high ductility,
but low strength and hardness. Low tempering temperatures will produce
low ductility, but high strength and hardness. In practice, appropriate
tempering temperatures are selected that will produce the desired level of
hardness and strength. This operation is performed on all carbon steels that
have been hardened, in order to reduce their brittleness, so that they can be
used effectively in desired applications.

Normalizing
Normalizing involves heating steel, and then keeping it at that temperature
for a period of time, and then cooling it in air. The resulting higher strength
and hardness, but lower ductility. Normalizing is performed on structures
and structural components that will be subjected to machining, because it
improves the machinability of carbon steels.

CASE CARBURISING :

 Case carburizing is a heat treatment process in which a gear is heated to a

temperature in contact with a liquid carbon which diffuse into the gear teeth
to a specific depth and making the surface hard leaving the core soft .

The case carburizing process as follows

 Preheating the component in tempering furnace upto 450°C for 2 hrs

 Shift the component to carburizing furnace at 620-630°C and rising
upto 750°C
 Liquid flow in 1mm LPH
 Increasing the temperature upto 910°C

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 Liquid continuesly for 8 hrs at a rate of 1.00 LPH

 Check 1st spy piece for case depth before stopping the carburising
fluid
 If case depth is less pass the fluid continuesly upto certain hrs and
stop
 Check 2nd piece for case depth and hardness
 If we get the desired hardness switch off the furnace and cool the
workpieces in the furnace

Case-hardening

Case-hardening is the process of hardening the surface of a metal object

while allowing the metal deeper underneath to remain soft, thus forming a
thin layer of harder metal at the surface
Process as follows
 Preheat the component in tempering furnace at 350-4050°C for 2 hrs
 Charge the component to carburizing for 800°C
 Heat upto 840°C in 45 mins.
 Heat for 2 hrs
 Cool to 800°C in furnace and oil quench for 1 hr
 Gear is water washed in washing machine using water at 60°C
 The hardness is checked
 Tempering is at temperature of 180°C for 3-4 hrs
 Air cooling is done
 Hardness is checked
 Shot blasting is done to remove the scales

5.3 THROUGH HARDENING

Through Hardening ("Quench & Temper") is a process used to increase the
hardness and tensile strength of material, and in alloy steels such as 4140
and 4340, will result in optimum combinations of strength and toughness.

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At Thermex, we have a variety of quench types available (oil, water, polymer,

air blast), thus allowing for the through hardening of a wide range of
materials including mild steels, alloy steels, tool steels, martensitic stainless
steels, and cast irons.

Dimensional change is inherent in quench and temper heat treatments,

because of the microstructural changes that occur.  For tight tolerance
parts, finishing allowances are required.  Always avoid sharp corners and
abrupt cross-section changes in parts that are to be through hardened. 

  5.4 BOGIE HEARTH FURNACE

The bogie hearth furnace is a special type of chamber furnace. The furnace
housing, through which access the effective space can be accessed on one
side via a manually movable bogie hearth coupled to a door system

This permits products that are to be heat-treated to be heated

homogeneously. Heating and cooling ramps can be adjusted with precision,
in line with process complexity and customer- or product-specific
requirements.

The process are as follows

 Load the raw material in furnace
 Heat upto 450°C for 2 hrs
 Increase the heating upto 550°C for 1 hr
 Keep increasing in series of 650(for 1 hr), 750(for 1 hr), 850(for 1 hr)
 And then obtain the temperature of 900°C for 2 hrs
 Cool upto room temperature inisde furnace

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4) MANUFACTURING PROCESS
 

Horizontal Bandsaws

Horizontal bandsaws cut through the stationary material with the blade
running on the horizontal. Prosaw's range includes small manual or semi-
automatic through to heavy duty automatic horizontal bandsaws

Manual Horizontal

TURNING FOR HOBBING

Turning is the machining process that gives shape to a raw material (metal,
wood, plastics, etc.). It is typically done using a machine called a lathe,
which can be CNC controlled or manual. Turning gear technology requires
proper equipment, and Gear Motions is equipped with machinery from Mori
Seiki to Okuma. Our skilled team is trained to produce high quality gears at
every stage of the process. Contact us for a quote!

Turning process of gear

HOBBING

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Hobbing machines provide gear manufacturers a fast and accurate method

for cutting parts. This is because of the generating nature of this particular
cutting process. Gear hobbing is not a form cutting process, such as
gashing or milling where the cutter is a conjugate form of the gear tooth. The
hob generates a gear tooth profile by cutting several facets of each gear tooth
profile through a synchronized rotation and feed of the work piece and
cutter.
Figure 1

DRILLING

Drilling is a cutting process that uses a drill bit 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. This forces the
cutting edge against the work-piece, cutting off chips (swarf) from the hole
as it is drilled.

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MILLING PROCESS

Milling is the process of machining using rotary cutters to remove material

by advancing a cutter into a workpiece. This may be done 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.

11.1 GEAR GRINDING

The increasing demand for efficiency and noise emission of gears

pushes the gear grinding process to its limits. With the widening
range of applications for automatic planetary transmissions and

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increased number of speeds (currently up to 10), gears in average get

smaller and smaller, while production volumes are increasing.

ECTRICAL DISCHARGE MACHINE (EDM)

Electrical discharge machining (EDM), also known as spark machining,

spark eroding, burning, die sinking, wire burning or wire erosion, is a
manufacturing process whereby a desired shape is obtained by using
electrical discharges (sparks) Material is removed from the work piece by a
series of rapidly recurring current discharges between two electrodes,
separated by a dielectric liquid and subject to an electric voltage. One of the
electrodes is called the tool-electrode, or simply the "tool" or "electrode,"
while the other is called the workpiece-electrode, or "work piece." The
process depends upon the tool and work piece not making actual contact.

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Wire Cut EDM Machine

5) DYNAMIC BALANCING

A balancing machine is a measuring tool used for balancing rotating

machine parts such as rotors for electric motors, fans, turbines, disc brakes,
disc drives, propellers and pumps. The machine usually consists of two rigid
pedestals, with suspension and bearings on top supporting a mounting
platform. The unit under test is bolted to the platform and is rotated either
with a belt-, air-, or end-drive. As the part is rotated, the vibration in the
suspension is detected with sensors and that information is used to
determine the amount of unbalance in the part. Along with phase
information, the machine can determine how much and where to add or
remove weights to balance the part.

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Dynamic Balancing Machine

6) COMPONENTS PREPARED

GEARS

GEAR TERMINOLOGY

Gear Terminology:

The following terms, which are mostly used to describe a gear, are as follow.

Face of tooth:

It is defined as the surface of the tooth above the pitch circle is known as
face.

Flank of tooth:

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The surface of the tooth below the pitch circle is known as flank.

Top land:

The top most surface of the tooth is known as the top land of the tooth.

Face width:

Width of the tooth is known as face width.

Pitch Circle:

It is an imaginary circle which is in pure rolling action. The motion of the

gear is describe by the pitch circle motion.

Pitch Circle diameter:

The diameter of the pitch circle from the center of the gear is known as pitch
circle diameter. The gear diameter is described by its pitch circle diameter.

Pitch point:

When the two gears are in contact, the common point of both of pitch circle
of meshing gears is known as pitch point.

Pressure angle or angle of obliquity:

Pressure angle is the angle between common normal to the pitch circle to
the common tangent to the pitch point.

Addendum:

Distance between the pitch circle to the top of the tooth in radial direction is
known as addendum.

Dedendum:

Distance between the pitch circle to the bottom of the tooth in radial
direction, is known as dedendum of the gear.

Addendum circle:

The circle passes from the top of the tooth is known as addendum circle.
This circle is concentric with pitch circle.

Dedendum circle:

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The circle passes from the bottom of the tooth is known as dedendum circle.
This circle is also concentric with pitch circle and addendum circle.

Circular pitch:

The distance between a point of a tooth to the same point of the adjacent
tooth, measured along circumference of the pitch circle is known as circular
pitch. It is plays measure role in gear meshing. Two gears will mesh together
correctly if and only they have same circular pitch.

Diametrical pitch:

The ratio of the number of teeth to the diameter of pitch circle in millimeter
is known as diametrical pitch.

Module:

The ratio of the pitch circle diameter in millimeters to the total number of
teeth is known as module. It is reciprocal of the diametrical pitch.

Clearance:

When two gears are in meshing condition, the radial distance from top of a
tooth of one gear to the bottom of the tooth of another gear is known as
clearance. The circle passes from the top of the tooth in meshing condition
is known as clearance angle.

Total depth:

The sum of the addendum and dedendum of a gear is known as total depth.
It is the distance between addendum circle to the dedendum circle measure
along radial direction.

Working depth:

The distance between addendum circle to the clearance circle measured

along radial direction is known as working depth of the gear.

Tooth thickness:

Distance of the tooth measured along the circumference of the pitch circle is
known as tooth thickness.

Tooth space:

Distance between the two adjacent tooth measured along the circumference
of the pitch circle is known as the tooth space.

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Backlash:

It is the difference between the tooth thickness and the tooth space. It
prevents jamming of the gears in meshing condition.

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TYPES OF GEARS

 Spur gears

 Bevel gears

 Helical gears

CARDON SHAFT

Cardon shaft (drive shaft) is a mechanical component which transmit power

from the transmission unit to the gear axles. The drive shaft also transmits
power when the gear box and gear axles are at an angle. As these cardan
shafts are subjected to high torque and subjected to shear stress, they must
be strong enough to bear the stress.

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The cardan shaft consist of parts such as Bearing cap, Cross, Yoke, Tube.

The various parts of cardan shafts and their manufacturing process are
explained below.

CARDAN SHAFT PARTS AND THEIR MANUFACTURING PROCESS

The cardan shaft comprises of bearing cap which holds the cross by needle
bearing. Yoke which supports the bearing cap and cross, and yoke is
connected to the tube which comprises of splines in case of slip cardan shaft

The cardan shaft are manufactured in two type as per the costumer
requirements. With slips and without slips. The figure below shows without
slip cardan shafts. Without slip means no axial movement of shaft is
permitted. In this type, yoke is welded to the yoke shaft and the shaft does
not contain any splines. The bearing cap are bolted to the yoke which in
turn carries the cross held by the needle bearings present inside the
bearing. In case of with slip cardan shaft the tube consist of splines
generated on the inner diameter by broaching process. The shaft has a
mating splines which made with the tube. The yoke is welded to the tube
and the tube yoke shaft are assemble. The bearing caps are bolted top the
yoke

The different types of cardan shafts are

 10C Cardan shaft

 12C Cardan shaft

 With slip

1) W12 Cardan shaft

2) W18 Cardan shaft

 Without slip

1) W38 Cardan shaft

Cardan Shaft parts and process

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1. Bearing Cap:
Bearing cap is a component which supports the cross with the
help of needle bearing. The bearing cap is bolted to the yoke. The various
process the bearing cap undergoes are,

 Rough turning: After receiving the forged bearing cap, the bearing cap
undergoes rough turning. The bore of bearing cap is rough turned
leaving the stock for grinding operation.
 Milling: The bearing cap base is milled on the vertical milling machine
removing the stock.
Minimum stock is left for the grinding operation.
 Drilling: Next operation the bearing cap undergoes is drilling. The
drilling is done on bearing cap to incorporate the bolts by which the
bearing cap is bolted to yoke. The drilling is carried on radial drilling
machine
 Spot facing: Spot facing is done on drilled hole face which
incorporates the washer while bolting of bearing cap to the yoke. The
spot facing is done on the radial drilling machine.
 Deburing: Sharp edged and bur are formed while performing the
drilling operation. Deburing is done to remove the sharp edges and
bur formed before proceeding to next process.
 Case carburizing and case hardening: The bearing cap is case
carburized and hardened to obtain a hard surface with soft and tough
core.
 Surface Grinding: The base of bearing which is milled in milling
operation is surface grind to specified limit to obtain a proper fit while
assembling it to yoke. The base is grind as per the limit on the surface
grinding machine.
 Internal grinding: The bore of bearing cap which is rough turned
undergoes internal grinding operation to obtain a dimension within
specified limit with good surface finish.
 Radius grinding: Radius grinding is done on the inner surface of bore
which helps to hold the retainer washer.
 Fitting (Deburing): After all the processes are finished, the bearing cap
undergoes deburing operations on all corners and edges to remove
sharp edges and burs and making the bearing cap ready for
assembling process.
 Inspection: This is the final process. The bearing cap is inspected for
bore diameter, surface finish, the height from bore to base.

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2.Cross
The cross is a part of cardan shaft, which is connected to the
yoke with the help of four bearing caps. Out of four bearing caps
connected to cross, two caps are bolted to yoke and other two left free
which get bolted to the main transmission unit at the customer end.
The cross acts as hook joint due to which the cardan shaft can be
connected to the axle at an inclined angle. The cross undergoes
following process:
 Rough turning: The forged cross undergoes rough turning removing
the material. In this process only material is removed and neglecting
the surface finish which is carried in the preceding process.
 Finish turning: In this the cross is finish turned and leaving a
minimum stock for cylindrical grinding where the material is removed
to the specified limit.
 Drilling: It is done on the cross end. An oil hole is drilled at right angle
to the previously drilled hole on the cross leg. This oil hole connects
all the drilled hole on all legs of cross.
 Fitting (Deburing): The bur formed during drill and milling operation
are removed using portable hand grind machine or using files.
 Case carburizing and case hardening: The cross is sent for case
carburizing process where the carbon is deposited on the cross
surface making cross surface hard to specific depth making it wear
resistance leaving the core soft and tough.
 Cylindrical grinding: The cross leg undergoes cylindrical grinding
where the dimension is brought to specified limit with good surface
finish.
 Fitting: After Cylindrical grinding, the cross is assembled in bearing
cap to check the fitment of cross in bearing cap and also any sharp
edges and bur are removed using portable hand grind machine.
 Inspection: After the cross piece undergoes all processes, it is
inspected for its dimension such as diameter, drill hole.

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3.Yoke
Yoke is a part of cardan shaft, which is welded to shaft
containing splines in case of slip cardan shaft. The bearing cap is
bolted to the yoke. The yoke must have a good surface finish and
dimension within specified for proper fitment. The processes yoke
undergoes are as follows:
 Rough turning: The forged component undergoes rough turning
operation, removing the material and leaving the minimum stock in
the material which is finished in the preceding process.
 Through hardening: The yoke undergoes through hardening process.
Yoke is preheated in the tempering furnace at 400-450C for 2hours.
The item is charged to carburizing furnace at 800C. Heat up to 840+/-
10. Then soak at this temperature. Cool to 800C and quench in oil
bath. Wash the part and check the hardness.
 Finish turning: After hardening the yoke undergoes finish turning
operation where the minimum stock left is rough turning is removed
obtaining specified dimension and surface finish. Operation is done
either on lathe or horizontal machining center.
 Milling: After finish turn, yoke undergoes milling operation. Face
milling, end milling, radius milling, key way operations are performed
on the yoke. The operation is done on Vertical milling machine (CNC
or Conventional).
 Drilling: It is done on the yoke face on which the bearing caps are
bolted. The drilling operation is carried on radial drilling machine.
 Fitting: Sharp edges, burs formed during the milling operation are
debured and removed in this operation. The portable hand grind
machine or files are used for this operation.
 Inspection: It is the final process of yoke. The yoke is inspected for its
dimension and checked whether the dimensions are within the
specified limit or not. The yoke is then welded to the propeller shaft.

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7) QUALITY CHECK AND INSPECTION

QUALITY

“Product quality means to incorporate features that have a capacity to meet

consumer needs (wants) and gives customer satisfaction by improving
products (goods) and making them free from any deficiencies or defects.

Three Types of Quality Inspection

1) Incoming Quality

2) Staging Quality

3) Final quality

 Incoming Quality Inspection

Inspection of all the desired dimensions of the incoming raw material.

1) Ultrasonic Machine – To determine inside cracks

2) U T Machine

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3) Chemical Analysis – To check the chemical properties of the

component material, inside the lab, taking a chip of the component

 Staging Quality Inspection

The inspection of the components takes when the machining of the parts
is going on.

Instruments Used

1) Vernier Calipers

2) Flange Micrometer

3) External Micrometer

4) Bore Gauge

5) Liver type Dial

6) Inside Micrometer

 Final Product Testing

1) Temperature

2) Speed

3) Sound Level

4) Vibrations

5) Ratio

8) CONCLUSION:
In review of the internship, it has been an excellent rewarding experience.
We have been learnt a lot of new things which will be very useful in my
future & have gained real industrial experience.

SAN Engineering and Locomotive Co Ltd are leading manufacturer and

assembly of Diesel locomotives. They manufacture gears, cardan shaft

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(propeller shaft), gar boxes, power packs. SAN. Mysore manufacture

individual gears, cardan shat and gear box assemblies.
During my work at SAN, Mysore I worked on modeling tool solid works to
create 3d model of gears using gear data are converted the 3d model into 2d
drawings. During this work I learnt many new modeling features in the solid
works.
During my work in the production department, I learnt how a production
schedule is generated and then how the work is carried according to the
schedule. How workers perform the work with the available tools and
equipment.
I learnt how a component is fixture on the machine bed and various
component setting such as centering the component to the table and then
fixing the cutting tool to the head spindle.
I learnt how the raw material is inspected to check any cracks in the
material occurred during the forging operation. ultrasonic testing is done to
check the cracks in the raw material.
I also learnt different types of cutting tool used for processing the gears and
cardan shaft. Then I
also learnt various heat treatment process and why they are carried on the
raw material before proceeding to various processes.
I learnt the process of drilling a hole into the gear or cardan shaft parts and
also the tapping process and how marking is done on gears and other parts
before drilling a hole.
I Learnt how a material is transferred from once machine to other machine
using a crane.
During my work in production floor, I learnt various safety precautions
taken while processing on the machine. I also learnt the production tool and
techniques adapted by the company one of them is 5S technique.

9) REFERENCES

1) John J. Uicker, Jr., Gordon R. Pennock and Joseph

E. Shigley, “Theory of Machines and Mechanisms,”
Oxford University Press, 4th Edition, 2014,
ISBN:9780199454167.

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2) S.S. Rattan “Theory of Machines” Tata McGraw-Hill,

New Delhi, 4th edition, 2015, ISBN:
9789351343479.

3) Robert L. Norton, “Kinematics & Dynamics of

Machinery,” Tata Mc Graw Hill., 1st Edition, 2009,
ISBN: 9780071278522.

DEPARTMENT OF MECHANICAL ENGINEERIN, PESCE, MANDYA. Page 27