INDUSTRIALTRAININGREPORTONINDOMOBILESALE&SERVICES

Maharashtra StateBoard OfTechnical

Education, Mumbai

IndustrialTrainingReport

On

IndomobilsalesandServicePvtLtd

MIDC,Dharashiv

Submittedby

Mr.Umbare Pruthviraj Vaibhav

Guided by – Mr. D. C. JADHAV

Department of Mechanical engineering
SVERI College of Engg. (poly.) (2023-24)

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MaharashtraStateboardof technicalEducation,

Mumbai

Certificate
This is to certificate that Mr. Pruthviraj Vaibhav Umbare from
SVERI college of Engg.(Poly.) college having enrollment no. 2324 has
completed Industrial Training Report having title Analysis Indomobil
Sales and services pvt Ltd MIDC,Dharashiv during academic year 2023-
24. the project completed by in a group consists of 5 candidates under
the guidance of MR. D. C. JADHAV

Mr.D.C. JADHAV
Guideteacher. HOD. principal

ACKNOWLEDGEMENT

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Iexpress,mygratitudeto allthosewhohelpedinstagesofthedevelopment of this

ITR Report firstly. I would like to express my sincere gratitude to teacher/guide Mr

sir. It is always said, that efficient work is nothing

butmutualcoordinationbetweentwoormorepeopleforme.itwasaverydifficult real

time project without the help of people surrounding me.

I am also, thankful to all faculty members of department of Mechanical

engineering for there to help inspiration and for helping me for preparation of

report and presentation for the more.

I would like pay my sincere thanks and gratitude to all. Finally, I thankful to all of

themwhodirectlyorindirectlyhelpedmeincomputationofthereportsuccessfully for

without their help this project would not have seen the light of the day.

ABSTRACT

ThisIndustrialTrainingreportisaboutIndomobilSaleandServices,MIDC

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Dharashiv This industrial training is done as partial fulfillment of the course from

MSBTE’sdiplomainmechanicalengineering.Thisreportcontainsfunctioningofthe

organization,differentdepartmentsofworkshopandweallstudentslearnhowthe

Carwork, which material is used, components used in car , Engine parts. We learn

about BS4 and BS6 engine. We understand how power developed in engine and

transmittedtowheelsThereportcontainsthebasicconceptsofcarandit’sworking along

with assembly etc . Also report contains functions of parts of car ,engine Assembly

and Dissemble etc

Index
Chapter Contentname PageNo.
No.
01 Introduction 06

02 Car Engine: Components And 07-10

theirfunctions&Terminology.

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03 CoolingsysteminDieselEngine 11-12

04 TransmissionSysteminCar 13-15

05 SuspensionSystem 16

06 BrakeSysteminCar 18
07 FuelSupplySystemofdiesel engine 19

08 StartingSystemAndCharging 20
System
09 HowtheEnginework&Power 21
developed ?
10 WorkingOfDieselEngine 21-23
11 AboutScrap 24
12 Summary/Conclusion 25
13 References 26

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INTRODUCTION

03/06/2024 Inthisday Weall studentsaregivethevisitat, “INDOMOBILE

SALE AND SERVICES DHARASHIV.”
• I Collecting the informationand analysis ofdepartmentor sections
available in this workshop under the Guidance of Hundekar Sir
• Inthisindustryrepairingandmaintenancedoneofcarcommersil vehical
• Morethan 30 worker’sareworksintheshowroom andworkshopunder the
Head of Department.
• Differentstoresections,,differentoffices,storesrooms,areavailablein the
workshop
• DifferentOfficershasdifferentauthorityandresponsibilityandtheygive the
orders to the subordinators and Supervisor.
• Weallstudentssaw theworkersandsupervisorsHow thecompletedtheir
working task in the period of time
• Nowweareseethefunctionofeachsectionandtheir information.

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2. CARENGINE:COMPONENTS,THEIRFUNCTIONS,TYPESAND
TERMINOLOGY

• ItisanInternalcombustionengineinwhichcombustionoffueltakeplaceinside
theengine.Whenthefuelburnsinsidetheenginecylinder,itgeneratesahigh
temperatureand pressure.
• Thishigh-pressureforceisexertedonthepiston(Adevicewhichfreetomoves
insidethecylinderandtransmitthepressureforcetocrankbyuseofconnecting
rod),whichusedtorotatethewheelsofvehicle.Intheseengineswecanuseonly
gasesandhighvolatilefuellikepetrol,diesel.

ComponentsofInternalCombustionEngine:
• CylinderBlock Camshaft
• Piston Valve
• PistonRings RockerArm
• ConnectingRod
• Crankshaft
• Flywheel

Cylinder Block :

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• Cylinder blockis the main body of IC engine. Cylinder is a part in which the intake of
fuel, compression of fuel and burning of fuel take place.
• The main function of cylinder is to guide the piston. It is in direct contact with the
products of combustion so it must be cooled. At the upper end of cylinder, cylinder
head and at the bottom end crank case is bolted. The upper side of cylinder is
consistingacombustionchamberwherefuelburns.
• To handle all this pressure andtemperature generated by combustion of fuel,cylinder
material should have high compressive strength. So it is made by high grade cast iron

Piston:

• A Pistonis fitted toeach cylinder asa face to receive gas pressureandtransmit the
thrust to the connecting rod. It is a prime mover in the engine.
• The main function of piston is to give tight seal to the cylinderthrough boreand slide
freely inside the cylinder. Piston should be light and sufficient strong to handle gas
pressure generated by combustion of fuel.
• Sothepistonismadebyaluminumalloyandsometimesitismadebycast iron
because light alloy piston expands more than cast iron so theyneed more clearances
to the bore

PistonRings:

• To provide a good sealingfitandless friction resistance between thepiston and

cylinder, pistons are equipped with piston rings.
• These rings are fittedingrooves whichhave beencutinthe piston.
• Piston rings are madeof cast iron offine grain andhigh elastic material which isnot
affected by the working heat. Sometimes it is made by alloy spring steel.

ConnectingRod:

• Connecting rod connects the piston tocrankshaft and transmits the motion and thrust
of piston to crankshaft.
• Itconverts thereciprocatingmotionofthe pistonintorotarymotionofcrankshaft.
• Therearetwoend ofconnecting rod;oneisknownasbigendandotherassmallend.
• Big end isconnected tothe crankshaft and the small end is connected tothe pistonby
use of piston pin.
• The connecting rods are made of nickel, chrome, and chrome vanadium steels. For
small engines the material may be aluminum.

Crankshaft

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• The crankshaft of an internal combustion enginereceives the efforts or thrust supplied

by piston to the connecting rod and converts the reciprocating motion of piston into
rotary motion of crankshaft.
• The crankshaft mounts in bearing so it can rotate freely. The shape and size of
crankshaft depends on the number and arrangement of cylinders. It is usually made
by steel forging, but some makers use special types of cast-iron such as spheroidal
graphitic ornickel alloy castings which are cheaperto produce and have good service
life.

Flywheel

• Flywheel is securedon the crankshaft. The main function of flywheel is to rotate the
shaft during preparatory stroke. It also makes crankshaft rotation more uniform
• Flywheel, heavy wheel attached to a rotating shaft so as to smooth out delivery of
power from a motor to a machine. The inertia ofthe flywheel opposes and moderates
fluctuations in the speed of the engine and stores the excess energy for intermittent
use.
• Gear teeth on the Flywheel are connected to thestarter motor And this stairMotor
Start the engine
Camshaft:

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• CamshaftisusedinIC enginetocontroltheopeningandclosingofvalvesatproper
timing. For proper engine output inlet valve shouldopen at the end of exhaust stroke
and closed at the end of intake stroke.
• So to regulate its timing, a cam is use which isovalin shapeand it exerts a pressure on
the valve to open and release to close. It is drive by the timing belt which drives by
crankshaft.
• Itis placedatthe topor atthe bottom of cylinder.

Valve:
• In an IC engine, the devices which are used to restrict and release theflow of inlet fuel
and exhaust gases are called engine valves.
• The valve which controls the flow of inlet fuelinto the combustion chamber is called
the inlet valve.
• The valvewhichcontrolstheflowofexhaustgasesiscalledtheexhaustvalve.

RockerArm:

• The rocker arm is thepart responsible for transmitting the movement of the camshaft
towards the intake and exhaust valves of the engine, a process that occurs throughthe
direct contact of these parts with the tappets and according to the movement of the
shaft
• Rocker arm is a centrally pivoted lever inthe valvetrain ofan engine that converts the
motion of the rods to open the valves. Rocker arms transmit motion from the cam
lobes to the valves.
• Rocker arms are typicallylocatedbetweenthepushrodandintake andexhaustvalves.

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3. CoolingsystemindieselEngine:WaterCoolingSystem

• The Engine cooling system is one of the necessary thing that is present in the Internal
Combustion Engine to reduce the temperature of the components inside the engine. It
also helps to reduce the wear out of the component and provide smooth functioning
and long life of the components.

• In Water Cooling Systemdissipation of heat is done by the circulation of waterthrough

the jackets around the cylinder and passes this hot water through the radiator where
air absorbs heat from the water.
• There aretwotypesof watercoolingsystem.
Thermosyphon
Pumpcirculationsystem

• Thermosyphon:
• Thepumpisnot fittedinthissystem.
• Circulation of water is done due to the difference indensities between hot andcold
water.
• However,in this cooling system,the rate of coolingis low. Nowadays itsusage is
limited because we need to maintain the water to a certain level

WorkingofThermosyphonSystem:

• TheThermosyphoncoolingsystemoperatesontheprincipleofnaturalconvec-tion.
• Thermo-syphonwater coolingsystem is based onthe fact that water becomes light on
heating and,
• The top and bottomof the radiator are connected to the topandbottom of the
cylinder water jacket respectively with the help of pipes.
• The radiator is cooled by causing air to flow over it. Airflow isachieved by vehicle
motion or a fan provided.
• The heated water inside the cylinder water jacket becomes light and moves out of the
upper connection pipe into the radiator and travels down from the upper tank to the
lower tank, and rejecting heat as it travels.
• This cooled water from the lower tank is passed into the cylinder water jacket and
hence circulated again for the process.
• The limitation ofthis system is that thiscooling depends only on temperature and is
independent of engine speed.

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WorkingofPumpCirculationSystem:
• Inthissystem,thedirectionofcooling waterflowisupwardfrom the
cylinder head to the toptank of the radiator, then down through the
radiator core to the bottom tank.
• From thebottom tank,itmovesthroughthelower radiatorhosetothe
cylinder block water jackets by the help of the water pump, which
circulatesthewater.
• Water enterstheengineatthecenter of theinletsideof thepump •The
circulating pump is driven by a belt from the crankshaft.
• Asenginespeed increases,theflow of coolantincreases. Partsof the
Water Cooling System:
Thesearesomemajorpartsofwatercoolingsystem:
Radiator
WaterPump
Fan
WaterJacketsaroundtheCylinders
HosePipe

Thermostat Valve

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Transmissionsysteminbuses

• Transmission system is one of the systems in the Passengers Bus.• It is used to

transmit power and torque from the engine to the driving wheels.
• It consists of Clutch,Gear box, Propeller shaft, Differential, Axles and the driving
wheels, Tires.
• There are different types of devices intransmissionsystem of automobile.They are •
Clutch. • Gearbox. • Propeller shaft. • Differential. • Axles and driving wheels
Clutch
• Clutchisamechanicaldeviceusedinthetransmissionsystemofavehicle.
• It engages and disengages the transmission system from the engine. It is fixed
between the engine and the transmission.

• Functionoftransmittingthetorque fromtheenginetothe drivetrain.

• Smoothly deliver the power from the engine to enable smooth vehicle movement.
Perform quietly and to reduce drive-related vibration.
• Protectthe drivetrainwhengiventhe inappropriate use.

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Gearbox
• The purpose ofa gearbox is to increase orreduce speed. As a result, torque output
will be the inverse of the speed function.
• If the enclosed drive is a speed reducer (speed output is less than speed input), the
torque output will increase; if the drive increases speed, the torque output will
decrease.
• InpassengersBusesSynchronizedGearisused.
Working:
• In the synchromesh gearbox, the Lay shaft isconnected to the engine directly, but it
rotates freely when the clutch is disengaged.
• Because the gears have meshed allthe time, the synchro brings the layshaft to the
right speed for the dog teeth to mesh to achieve the desired speed of the output
shaft.

Componentsofgearbox
• EngineShaft
• LayShaft
• OutputShaft
• Gears onLayshaft
• GearsonOutputshaft
• Cone
• SynchronizerHub
• SlidingSleeve
• SynchronizerRing
• Andeachparthas differentFunctions

Propellershaft
• The function ofthe propeller shaft is to transmit torque between the transmission,
the transfer case and the driving axles.

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The propeller shaft makes it possible to connecttwo axes of rotation which are not
exactly in the same plane.

• Propeller Shaftis the shaftthattransmits power from the gearbox tothe differential
gear in a motor vehicle from the engine to the propeller in a boat or flying machine.
• Propeller shaft, sometimes calleda cardan shaft, transmits power from the gearboxto
the rear axle.
• Regularly the shaft hasa tubular section and is made in maybea couple piece
construction.
• Following arethemainpartsofthepropellershaft:
UOrUniversal-joint.
U-joint
Tube.…
CentreBearing.…
Midship Shaft.…
EndYoke.…
SlipYokeandTubeYoke.…Flanges.
 AndDifferentParthasdifferent Functions.

Differential:
• The differentialis a system thatallows thedrive wheels to turn at different speeds,
which is required when the car is negotiating a turn.

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In a turn, the outsidewheel must travel farther, which means itmust travel faster than
the inside wheels
• Following aretheComponentsOfDifferential
DrivepinionorBevelpinion
RinggearorCrownwheel
Differential case
Differentialsidegear orSungears
Differentialpinionsor Planetgears
AxleshaftsorHalf shafts
PinionshaftorCrosspinorspider

AxleAnddriving Wheels:
• An axle is a rod or shaft that connectsa pair of wheels to propel them andretainthe
position of the wheels to one another
• Inotherwords,axlesdeliverthedriving powerfromtheenginetothewheels.
• Theymaintaintheposition ofthewheelsrelativetoeachotherandtothebusbody
• The wheel and axle form a kind of roundlever. Thecenter of the wheel and axleis the
fulcrum of the rotating lever. Asthe wheeland axlerotate, the wheel moves a greater
distance than the axle, but it takes less effort to move it. The axle moves a shorter
distance, but it turns with greater force.

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Tires:
• The main functions of a vehicle’s tires include supporting the vehicleload, transmitting
traction and braking forces to the road surface, absorbing road shocks.
• Andchanging andmaintainingthedirection oftravel.
• Thetwomainsyntheticrubberpolymersusedintiremanufacturingarebutadiene
rubber and styrene butadiene rubber. These rubber polymers are used in combination
with natural rubber.

Suspensionsystem

• Busisapassengervehiclethatutilizessolidaxleastheprimarysuspensionsystem.
• A solid axle consists ofa centraldifferential in a single housing that alsocontains the
drive shafts that connect the differential to the wheels.
Theaxleistypicallysuspendedwithleafspringsandshockabsorbers.
• The mainfunctionofleafspringsistoprovidecomforttothepassengersby
minimizing theverticalvibrationcaused bythenonuniformity ofroadgeometry.
• The desired leaf spring material should have high strength and low modulus of
elasticity in the longitudinal direction.

 Construction

• LeafspringsareacrucialpartofthesuspensionsystemofaBus.
• They consist of anumber of layers of leaves withagradation in their size, thebigger
layer being on the top with each layer joined to the other.
• Leaf springs are directly attachedto the frame, either at both ends or at one end. For the
latter, the front end is attached to the frame while the other end is attached to a short
swinging arm through a shackle.

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BrakeSysteminCAR

• The Main Function ofbrake is tostopthecar or any vehicle And In car Airbrake system is
used.
• Air brakes are typically usedon heavytrucks and buses. Typicaloperating pressure is
approximately 100–120 psi or 690–830 kPa or 6.9–8.3 bar. A compressed-air-brake
system is divided into a supply system and a control system.
• Indiesel buses, the braking system consists of air brakes. Since air is plentiful but
hydraulicfluidcouldget lost in aleak, big vehiclesrely on air-poweredbrakes tokeep
drivers and everyone else on the road safe

 Working

• Air brake canbe eitherdisc brake or drum brake

• Air is pressurized by an enginemounted compressor,The air compressor pumpsthe air
into theair storage tanks which store the compressed air until it’s needed.
• Air pressure is used to apply the service brakes and release the parking brake. There
are multiple air circuits inthe system. The parkingbrake engages by springforce in the
parking brake portion of the spring brake chamber when the air pressure in the
chamberisreleased.
• This also allows the parking brake to be used as the emergency brake system. If air
pressure was to drop too low, the force exerted by the spring in the chamber will be
able to overcome the force exerted by the air on the diaphragm and applythe brakes
on all wheels.
• You might think ofair brakes as working similarly to a hydraulic brake circuit. As with
hydraulic brakes, when the driver presses the brakepedal, airpressureis applied, like
hydraulic pressure in a hydraulic brake circuit to the wheel when applying the brake.

FUELSUPPLYSYSTEMOFDIESELENGINECAR

• During engine operation, the fuelis supplied by gravity from fueltothe primary filter
where coarse Impurities are removed.
• From the primaryfilter, the fuelis drawnby fueltransfer pump and is delivered to Fuel
injection pump through second fuel filter.
• The fuel injection pump supplies fuel under high pressure to The injectors through
high pressure pipes.
• The injectors atomize the fuel and inject it into thecombustion Chamber of the
engine.

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• Thefuelinjectionpumpisfedwithfuelinabundance.
• The excess fuel is by-passed Tothe intake sideof the fuel transfer pump through a
relief valve.
• Themaincomponentsofthefuelsystemindieselengineare
• FuelFilter
 fuelliftpump
 fuelInjectionpump
 atomizersand
 highpressurepipe
FUEL INJECTION SYSTEM
• Diesel fuel is injected in diesel engine through injectors with thehelp of fuel injection
pump.
• The system Using injectors, fuel injection pump, fuel filter, and fuel lines is called fuel
injection system.
• ThemainFunctionsoffuelinjectionsystemare:
• Tomeasurethecorrectamountoffuelrequiredbyenginespeedandload,
• Tomaintaincorrecttimingfor beginningandendofinjectionpump
• Toinjectthe fuelintothe combustionspace againsthighcompressionpressure.

STARTINGSYSTEM&CHARGINGSYSTEMThe
startingsystem:
• Generally accepted methods ofstarting of diesel engine is electric starter . The electric
starter usually consists of a 12-volt battery and a 12-volt starting motor along with
suitable auxiliary components.
• The keycomponents ofthe starter system are:–Battery–Starter (ignition)switch
(part ofthe ignition lock) – Starterrelay – Starter motor – Starter gear ring mounted
ontheflywheelThebatteryprovidestherequiredelectricalenergyduring start—up

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• An inhibitor or aneutral safety switch is included inthe starting system circuit to

prevent the vehicle from being started while in gear.
• When the ignition key is turned tothe start position, current flows and energizes the
Starter’s solenoid coil.
• Theenergized coilbecomesanelectromagnetwhichpullstheplungerintothecoil.
The plunger closes aset of contacts whichallow high current toreach the starter motor.
Thecharging system:
• The chargingsystem consistsof an alternator (generator),drive belt,battery,voltage
Regulator and the associated wiring.
• The chargingsystem, like the starting system is a series Circuit withthe battery wired
in parallel.
• After the engine isstarted and running, the alternator Takes over as the source of
power and the battery then becomes part of the load on the charging System.
• The alternator, which is driven bythe belt, consistsof a rotating coilof laminatedwire
Called the rotor. Surrounding the rotor are more coils of laminated wire that remain
stationary (called stator) just inside the alternator case.
• When current is passed through the rotor via the slip Ringsand brushes, the rotor
becomes a rotating magnet having a magnetic field.
When a Magneticfield passes through a conductor(the stator), alternating current (A/C) is
generated.

HowTheCarEngineWorkAndPower Developed?

• Conceptually, diesel engines operate by compressing air to high pressure/temperature

and then injecting a small amount of fuel into this hot compressed air.
• The high temperature causes the small amount ofhighly atomized injected fuel to
evaporate.

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• Mixing with the hot surrounding air in the combustion chamber, the evaporated fuel
reaches its auto-ignition temperature and burns to release the energy that isstored in
that fuel .
• The diesel engine gainsits energyby burning fuel injected or sprayed into the
compressed, hot air charge within the cylinder.
• The air must beheated to a temperature greater than the temperature at whichthe
injected fuel can ignite. Fuel sprayed into air that has a temperaturehigherthanthe
“auto-ignition” temperatureof the fuel spontaneously reacts with theoxygen in the
air and burns.
• Air temperatures aretypically in excess of 526 °C (979 °F); however, at engine startup,
supplemental heating of the cylinders is sometimes employed, since the temperature
of the air within the cylinders is determined by both the engine’s compression ratio
and its current operating temperature.
• Diesel engines are sometimes called compression-ignition engines because initiation
of combustion relies on air heated by compression rather than on an electric spark.
• In a diesel engine, fuel is introduced as the piston approaches the topdead centre of
its stroke.
• The fuel is introduced under high pressure either into a pre combustion chamber or
directly into the piston-cylinder combustion chamber. With the exception of small,
high-speed systems, diesel engines use direct injection.

WorkingOfDieselengineofcar

• In diesel engine , there are 4Working processes, suction step when piston moving
down, compression step when piston moving up, burning step when piston moving
down, the last is exhaust step when piston moving up.

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• From that statement, we can learnthat 4 stroke engine produce combustion in every 2
revolutions of crankshaft.
 SuctionStroke:
Thesuctionstepisalsocalledintakestroke,thatistheprocessofenteringtheairinto the
cylinder chamber. Thisair intake occurs when the piston moves down from TDC (top
dead center) to BDC (bottom dead center). This movement will increase the volume in
the engine cylinder.
• In other side inlet valve open, as a result the piston will suck the air from the intake
manifold, so that air from the outside enters the intake valve fillingthe cylinder cham
chamber.

 CompressionStroke:
• The compression step is the process of compressing the airinsidethe cylinder
chamber.
• This compression step takes place after the suction step, when thepiston hasreached
BDC at the end of the suction step, the piston will again rise to the TDC.
• As a result there is a narrowing of the cylinder volume. In this condition both the
intake valve and exhaust valve are closed, so that the narrowingof the cylinder space
will compress the air inside.

 Combustion/PowerStroke:
Thecombustionstepisthemainprocessoftheengine.Inthisprocessthedieselisfed through the
injector into the combustion chamber.

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• As We discussed, the air temperature will rise until above of diesel burning point. And
when the piston reaches TDC, the air is already in its highest temperature level
(exceeding the diesel burning point).
• In thiscondition, the diesel injected via injectors, it make the fuel atomized through
the injector. As a result, there was a burning that produced expansion power.
• This expansion power will push the piston to move down to the BDC. The expansion, is
also use to make the vehicle run. Because the power is so high.

 ExhaustStroke:
• The exhauststepistheprocessofremovingcombustionresidualgasesfrom the
combustion chamber.Thisprocess occurs when thepistonreturns to TDC after being
exposed to the expansion of combustion power.
• At this step, the exhaust valve opens sothatthe upward movement of the piston will
push the combustion residual gas to get out into the exhaust manifold.

AboutScrap

• Scrapmeans “Whenabus hasnouse leftandis convertedintoscrap”

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• Scrapconsistsof recyclable materials,usuallymetals,leftoverfrom product

manufacturingandconsumption,suchaspartsofvehicles,supplies,andsurplus
materials. Unlike waste, scrap has monetary value,especially recovered metals, and
non-metallic materials are also recovered for recycling.
• Once collected, the materials are sorted into types — typically metal scrap will be
crushed, shredded, and sorted using mechanical processes.
• Scrap recycling is important for creatinga more sustainable economy or creating a
circular economy, using significantly less energy and having far less environmental
impact than producing metal from ore.

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Summary/Conclusion

• allthestudentscollecting theInformationabouttheworkshopon
• And we gain the basic knowledge of car and commercial vehical their working
principle etc. under the different sections mentors .
• WelearntheHowtheAssembleAndDisambledtheEngineparts,theirlocationetc.

• We all students under We standthe types of engines in the Car andCompany for
example TATA,Mahindra,suzuki,Hyundai etc.
• We are learn How the power developed insidetheengine ?and How transfer the
power upto the driving wheels
• Weunderstand typesofenginesuch as

BSFOURTH
BSSIX
• AndtheirFiringOrderetc.
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• IunderstandallconceptofCarandcommercialvehicle

References:

• https://afdc.energy.gov/vehicles/how-do-diesel-vehicle-work
• https://en.m.wikipedia.org/wiki/Diesel_engine
• https://en.m.mahindra.IndomobilSALE/SERVICES

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