CHAPTER – 1

INTRODUCTION
Our M.D. Mr.D.R.SubramanyaB.Sc., B.E., a first generation entrepreneur;
Incorporated M/S Fitwel Tools and Forgings Pvt. Ltd. in the year 1983. Commercial
production commenced in the year 1987 with the manufacturing of Hand tools as core
business.

Five years later, Fitwel moved towards the Automobile industry through the
manufacturing of Maruti Udyog Rocker arms through M/S Sansera Engineering Pvt. Ltd..
The high precision demands both on dimensions and weight have since become a norm at
Fitwel.

M/S Fitwel Tools and Forgings Pvt. Ltd. was ISO/TS 16949:2009 certified in the year
2002 and has been ISO/TS 14000 certified in the year 2014. Fitwel became a Subsidy of M/S
Sansera Engineering Pvt. Ltd. in the year 2005.

Having started as a small scale industry with only one hammer line, we have gradually
grown and have 17 forging lines, comprising hammer, friction screw press and pneumatic
press lines and a well-equipped CNC shop.

Today, our forging output is 2 Million components a month and machined output is
close to 100,000 components every month. We cater to the Auto sector, Power tools, Hand
tools, Heavy machinery, Agricultural and Special purpose markets.

Our current scope of manufacturing is in precision forged components, ranging

from 18gm to 5,000gm.

All forging related heat treatment operations are carried out in-house and is monitored
and controlled by a well-equipped metallurgical lab.

Forging Die and Tool Design / manufacturing is carried out in-house by our fully
equipped design dept. and tool room, thus ensuring direct control over the quality of all the
products.

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 Value addition through value engineering and customer satisfaction is at the core of
our business and focus.

VISION
To achieve and maintain leader ship in precision forging industry through customer
satisfaction and improvement methods.

MISSION
Superior products and service to automobile industries.

To maintain market leadership through quality, cost efficiency and modern manufacturing
technology.

SCOPE

Manufacture, Sales and Supply of Precision Forged Rocker Arms, Connecting Rods,
Gear Shifters, Levers, Shafts, Flanges for Automotive Applications. Without element 7.3
(Product Design)

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 PRODUCT PROFILE

The company manufacturing an import substitution, precision, forged automatic

components in large volume to the original equipment manufacturers. The company
specializes in the manufacture of valve Rocker Arms the company also developed various
Fork Gear Shifter Connecting Rods, control Levers Spider Cross/ Universal joint forgings
and other precision forging for diesel pumps to motor vehicles.

The major products produced by the company:

 VALVE ROCKER ARM: It is a component which is adjusted to the tappets of

Two-wheeler.

 CONNECTING RODS: It is used to connect the engine and other parts in

two-wheeler.

 FORK GEAR SHIFTER: It is used in two-wheeler segments for shifting

gears.

 CONTROL LEVERS: The control levers are used to control the gear in the
four wheeler segment.

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 CUSTOMER

Sansera Engineering Pvt Ltd

Rocker Arms, Gear Shift Fork, Connecting Rods, Crank Shaft (Under Development)

Inland:
• Maruti Udyog Ltd

• Bajaj Auto Ltd,

• TVS Motors Ltd,

• Greaves Ltd

• Yamaha Motors Ltd.

• Honda Motor and Scooters India Ltd,

• Kinetic Engineering Ltd, and LML Ltd

Overseas:
• Lombardini F.I.M.S.P.a of Italy (OE)

• Ruggerinin MOTORIE S.P.A. of Italy (OE)

• Piaggio (Italy)

• Diesel Technic GmBH Germany (After Market)

• Truck Tech GmBH Germany (After Market)

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 Padded Rocker Arms

Roller type rocker arms

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 Control Levers / Tension Levers

Barrels

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 RAW MATERIALS
The actual process starts with the inspection of the incoming raw materials supplied
by the customer. The major customers are FACOR STEELS and SUNFLAG.
The sample of the raw material is subjected to inspection. If they find any cracks,
holes etc they are rejected. The incoming raw materials will be in the form of coils and rods
(materials of dia below 22mm will be in the form of coils) each coil weight about 1420kg and
it has to be decoiled.
Decoiling is the process of making the coil raw materials into straight rods. One coil
can be cut into 84 rods. Each of length 24ft. each coil needs 1.25-1.50 decoiled in one shift.
These raw materials are imported from Mumbai, Nagpur.

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 FITWEL TOLLS AND FORGINGS PVT. LTD.
LIST OF RAW MATERIALS WITH COLOUR CODE.

Sl. No. Name of the raw Materials Colour Code

1 20 Mn Cr 5 VIOLET

2 S45C/C-445/CK 45 WHITE

3 SAE 1035 BLUE/RED

4 C 15 RED

5 EN 353 BROWN

6 EN 19 BLACK

7 SCR 420 H GREEN

8 EN 8 WHITE/GREEN

9 R 10 S 10 U BLUE

10 16Mn Cr 5 YELLOW

11 40 CAD Pb 612 BLACK/RED

12 AS SZ 04 BLUE/WHITE

13 SCM 420 H YELLOW/GREEN

14 MS RED/WHITE

15 SAE 8620 BLACK/GREEN

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 MATERIAL RUNNING HEAT NO
Material Diameter Heat No GRN No

20 MNCR 5  2mm M 35116 1004

20 MNCR 5  18.3mm M 35117 1219

SER 420 H  22mm M 33584 514

SER 420 H  20mm M 36202 1321

SER 420 H  18.3mm M 35203 1021

S-45 C  18.3mm M 34419 A 670

C-15  20mm 57204 1628

Raw Materials

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 Decoiling Process

Stock of raw materials

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 Colour Coding

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Aryabharathi Polytechnic, Tumakuru. Dept. of Mechanical Engg. Page | 12
 QUALITY DEPARTMENT

"Quality itself has been defined as fundamentally relational: 'Quality is the ongoing
process of building and sustaining relationships by assessing, anticipating, and fulfilling
stated and implied needs.'

QUALITY MANUAL
ISO/TS 16949: 2002 certified company

The organization shall establish is maintain a quality manual that includes:

o The scope of the quality management system including details of and

justification for any exclusion.

o The documented procedures establishments for the quality management system

or reference to them.

o A description of the interaction between the processes of the quality

management system.

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 QUALITY MANAGEMENT
SYSTEM
The organization shall establish documents, implement and maintain a quality
management system and continually improve its effectiveness in accordance with the
requirements of this international standard.

Identifies the processes needed for the quality management system and their
application throughout the organization.

Determine the sequence and interaction of these processes.

Determine criteria and methods needed to ensure that both the operation and
control of these processes are effective.

Ensure the availability of resources and information necessary to support the

operation and monitoring of these processes.

Monitor measure and analyse these processes.

Implement actions necessary to achieve planned results and continual

improvement of these processes.

QUALITY OBJECTIVES
 Zero customer complaint.

 Maintain 100% delivery performance.

 Maintain in-house rejection within 2%

ISO/TS 16949: 2002 certified company

Top management shall ensure the quality objectives, including those needed to meet
requirements for product are established at relevant function and levels within the
organization. The quality objectives shall be measurable and consistent with the quality
policy. it shall be included in the business plan and used to display the quality policy.

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 QUALITY POLICY
To achieve and maintain leadership in precision forging industry and customer
satisfaction and control improvements methods.

ISO/TS 16949: 2002 certified company

Top management shall ensure that the quality policy they are as follows:

 Is appropriate to the purpose of the organization.

 Includes a commitment to complete with requirements and continually improve
the effectiveness of the quality management system.
 Provides a framework for establishing and reviewing quality objectives.
 Is communicated and understood with the organization.
 Is reviewed for continuing suitability.

RESPONSIBILITY FOR QUALITY

Managers with responsibility for corrective action shall be promptly on formed of
products or processes which do not confirm to requirements.

Personnel responsible for product quality shall have the authority to stop production to
correct quality problems. Production operation across all shifts shall be staffed with
personnel in charges of or delegated responsibility for ensuring product quality.

PERSONNEL SAFETY TO ACHIEVE

PRODUCT QUALITY

Product safety and means to minimize potential risk to employees shall be addressed
by the organization, especially in the design and development process and in manufacturing
process activities.

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 PROCEDURE FOR 5S
 Keep shop floor clean.
 Ensure the unwanted items stored in your place.
 If unwanted items found in your place keep it in RED TAG AREA.
 Ensure an unwanted item stored in your place, unwanted items to be stored
RED TAG area review to be done with management once in 15days for
disposal RED tag area.
 Gang ways to be remarked once in 15days.
 Components should not be lie on the floor.
 Ensure the tools measuring instruments to keep on the respective places.

Hardness Detector

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 ‘V’-BLOCK DIGITAL VISUAL HEIGHT GUAGE SURFACE
PLATE.

Ready for Dispatch as per customer

requirement

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Aryabharathi Polytechnic, Tumakuru. Dept. of Mechanical Engg. Page | 18
 Man power:

Number of employees:
FTF Company there are 350 to 400 members are working as a employee.
In management level 45 members are working, in middle and low level 300 to 350 members
are working.
Recruitment:
Recruitment means searching for a prospective employee and stimulating them to apply for a
job
Through difference Source Company will get hirer the candidates,
Such as,
 Employment exhibition
 Job portal
They hirer the candidates like ITI candidates, BE candidates, and diploma candidates.
Pay roll
ESI (employee state insurance):
Employee will get benefit form government, they do the medical checkup with free of cost.
For these ESI employee has to contribute 1.7% for these insurance and company has to
contribute 4.7% to this insurance. In this ESI employee family will also get benefit of
insurance.

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Professional tax:

Employee who is getting above 15000 they have to pay 200 Rs from a salary, which are
getting below 15000 they have to pay 100 to 150 rupees from his salary to the government.

PF (provident fund)

Provident fund means in employee salary they will get detected some amount of salary that is
12% on his salary basis and employer will also contribute 12.4% to employee PF.

Swipe card:

Special machine has been installed to know about in time and out time.

Of the employee i.e. Through thumb impression.

Promotion:

Promotion will be given by based on employee experience and also according to skill matrix
chart.

Every year management level employee get hike (salary hike) on there performance basis.

The feature of any company hinges on its ability to:

1. Attract and retain talent.
2. Evolve performance parameters with respect to key result areas.
3. Manage expectations.
4. Performance appraisal and reward system.
5. Competence mapping for building leadership.
6. Train and update skill sets.
Activities of hr department of FITWEL TOOLS AND FORGINE PVT LTD:
1. Manpower planning.
2. Recruitment.
3. Performance Policy.
4. Training.
5. Motivation and Empowerment.

1. Manpower planning: FTFL forecast personal needs, assesses personal supply and
match supply demand factors through personnel related programmer. to achieve long term
objectives regular manpower planning is essential.

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2. Recruitment: FTFL recruit qualified and experienced persons to right jobs. Recruitment
is based on, interview. Training and development after recruitment, training is given to fresh
employees to develop specific skills, impart knowledge and abilities so that current
employee's performance can be increased which in turn increases productivity.

3. Performance appraisal: Employees performance is measured with such factors as job

knowledge, quality and quantity of output, cooperation, versatility, health etc.

4. Promotion policy: works men promoted on basis of

1. Vacancy
2. Seniority
Staff's are promoted on basis of :
1. Merit cum seniority
2. Performance

Orientation training:
The orientation for all newly inducted employee is organized by personnel department
and training is imparted on the following subjects as shown against each of the following
5s (house-keeping)-personnel department
Plant and departmental procedure- plant manager
Safety policy and procedure – plant manager
On the job training:
Training program is organized by every department for the following area
 Plant Safety Procedure (PSP)
 Machine Operating Procedure (MOP)
 Job Safety Analysis (JSA)
The common training subjects for all employees are
First aid – safety awareness
Sanitation and house keep.

Training
FTF has established procedures for resource management FTF/QAP/0601 for
identifying the training needs and achieving competence of all personal performing activities
quality. Personal performing specific assigned tasks are qualified on the basis of education,
training, skills and/or experience, as required. It is ensured that the customer specific
requirements are understood and special attention is given to satisfying these needs.

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Training Records:
Training records are maintained by personnel department for all in-house programs,
including on-the-job training. Personnel department records all training programs in
“Employee Training Record” for every individual.

In case of In-house training programs conducted by internal and external sources for an
identified group of employees, the details are entered in training record, which is signed by all
employees attending the program. One copy is sent to personnel department for making entry
in “Employee Training record”.

Record of training feedback receives from the trainers and their and their sectional heads are
maintained by personnel department.

Feedback:
Employees undergoing other than On-The-Job training give feedback on the adequacy
and effectiveness or training programs in the feedback from to personnel department.

Motivation and Empowerment:

a) Incentive scheme: An effective production incentive scheme shall be maintained to
the employees who achieved the target productivity. In addition to attendance bonus also shall
be provide to the employees who attend full working days in a month.
b) Suggestion scheme: Suggestion are invited from the employees for improvement.
The suggestions are collected & reviewed by CFT for feasibility and it is sent for the approval
of MD. If it is approved, the suggestion is implementing and the same shall be in management
review meeting.

Competence, Awareness and training:

 Determined the necessary competence for personnel performing work affecting
product quality
 Provided training to take other actions to satisfy needs
 Evaluation of the training effectiveness of the action taken
 Ensure that the personnel are aware of the relevance and importance of their activities
and hoe they contribute to the achievement of the quality objectives and
 Maintained appropriate records 4 of education, training, skills and experience

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Work environment:

FTF has determined and manages the work environment needed to achieve conformity
to product requirements.

Personnel safety to achieve product quality:

Product safety and means to minimize potential risks to employees are addressed by
FTF especially in design and development process and in manufacturing process activities.

Cleanliness of premises:
FTF maintains the premises in a state of order, cleanliness and repair consistent with
the product and manufacturing process needs.

Policy manual:
The company Human Resources policy manual has been developed to facilitate the
implementation and clearly define company’s policies on human resource management.
The Manual provides guidelines to be followed ion the administration of these policies, and
assists all employees in defining who is responsible for each human resource management
decision and the correct which is to be followed.
The policies specified within are consistent with those of best practice management
principles. They have the full support and commitment of company management.
HR policies must be kept current and relevant. Therefore, from time to time it will be
necessary to modify and amend some section of policies or for new procedures to be added.

Some basic HR Policies:

1. Personal conduct:
Company expects its employees to achieve and maintain a high standard of ethics,
professional conduct and work performance to ensure the company maintains its reputation
with all internal and external stakeholders.
Application:
The policy will be seen to be successfully applied when all employees are seen to
perform their duties professionally with skill, care and diligence
This includes:
 Observing company policies and procedures
 Treating colleagues with courtesy and with respect for their rights, duties and
aspiration

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 Employees who do not conform to this standard of conduct will be subject to
disciplinary action as detailed in this manual

 Dress code
 Personal communication
 Phone calls
 Email
 Internet

2. Equal Employment Opportunity

Company provides equal employment opportunity to all qualified persons without

discrimination on the basis of age, sex, race, disability, marital status or religion in accordance
with applicable local, state and national laws and regulations.

All employment and promotion decisions will be based solely upon individual’s
qualification 006Es, experience, prior contribution and demonstrated capacity to perform at
higher or improved levels of performance and will be ion accordance with the principle of
equal employment opportunity. Company will take whatever affirmative action is necessary
to attract and retain qualified persons.
The Equal Opportunity Employment process is reflected throughout Company’s staff
recruitment and retention processes.

3. Healthy, safety and environment

Company is committed to providing and maintaining a safe work environment for the
health, safety and welfare of our staff, contractors, visitors and members of the public who
may be affected by our work.

To do this, company will:

 Develop and maintain safe systems of work, and a safe working environment
 Provide information and training at all levels in the organization to enable all
employees to support this policy
 Require all risks to be assessed prior to engaging in new areas of operation,
purchasing new equipment, and implementing new work methods, and that
these risks continue to be reviewed
All persons who are responsible for the work activities of other employees will be held
accountable for:

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  Identifying practices and conditions which could injure employees, clients, members
of the public or our environment
 Implementing steps to control such situation
 If unable to control such practices and conditions, reporting these to their superiors

Company demands a positive attitude and performance with respect to health, safety and the
environment by all employees, irrespective of their position.

1 Smoking
2 Alcohol, drugs
3 Worker’s Compensation

HR policy:

 To create learning is constantly improving skills and competency levels of employees.

 To enhance involvement and participation of employees in all initiatives for achieving

organizational goals.

 To plan the man power accurately.

 To manage the work environment needed to achieve conformity to product

requirements.

 To provide and maintains the infrastructure like buildings, workspace, supporting

process (such as transport or communication), and process equipment (both hardware
and software).

 To maintain its premises of order, cleanliness and repair consistent with the product
and manufacturing process state.

HR development through training and education of employees on:

 Attitudinal change.

 Skills development.

 Quality development.

 Cost conscious.

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A Study on Safety measures taken by Fitwel tools
and forgings to there employees:
Safety is the state of being "safe" (from French sauf), the condition of being protected against
physical, social, spiritual, financial, political, emotional, occupational, psychological,
educational or other types or consequences of failure, damage, error, accidents, harm or any
other event which could be considered non-desirable. This can take the form of being
protected from the event or from exposure to something that causes health or economical
losses. It can include protection of people or of possessions.

As fitwel deals with manufacturing of automobile spare parts, they have to work with hot iron
rods which are very dangerous to the health and safety of the employees. So the company has
been taken so many safety measures to protect and to safe guard the employees.

The safety measures taken by the company are as follows:

o Shoes and Uniforms

2. Helmets and Ear plugs

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3. Hand gloves, Goggle, Mask:

4. Special Jacktes, forehead gaurds, Face glass

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Scrap Maintenance:
Proper disposition of a discarded or discharged material in accordance with local
environmental guidelines or laws.

Here scrap refers to waste which is unwanted for the industry and also for the
customer who have given order for that particular component. The forged unit contains both
the component part and scrap part. The component part is seperated which is necessary and
the scrap part is considered as waste for the company.

The unwanted scraps cannot be thrown where ever they want, so these scraps were
collected and dumped in a particular place called “scarp yard”. In this particular place all the
scraps are collected and maintained.

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 The company has appointed so many employees to collect and maintain the scarps.
Even though the scrap seems to be waste, but the company is earning about Rs.400000 profit
per year. This is the special features of the company. The company have the ability to get
profit from unwanted waste i.e, scrap.

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 SUGGESTION

Kanban is a Japanese word which means signboard or labels.

Kanban is of two types are as follows:

1. Production kanban.
2. Withdrawal kanban.

Parts in the workshop are kept in containers. Only a specific number of these
containers are provided to the he workers in each work place. When all the containers are
filled, the machines shut off. No more parts are produced until the subsequent work center
provides another empty container. Thus work in progress inventory is limited to available
containers. The parts are provided only when these are needed. If a process stops because of
machine breakdown or quality problems, all preceeding processeswill automatically stop.
Alternatively, they will stop when there parts’ containers become full.

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 CHAPTER – 2

Technical knowledge of Hammer Shaft

Technical knowledge of Hammer Shaft includes:

1. Design and materials: Understanding the design, materials, and manufacturing

processes used to create hammer shafts.

2. Mechanical properties: Knowledge of the mechanical properties, such as strength,

toughness, and hardness, that are required for a hammer shaft to withstand impact and
stress.

3. Dimensional tolerance: Understanding the importance of precise dimensional

tolerance to ensure proper fitment and function.

4. Surface finishing: Knowledge of surface finishing techniques, such as grinding or

chrome plating, to enhance durability and performance.

5. Assembly and maintenance: Understanding how to properly assemble, maintain, and

repair hammer shafts to ensure optimal performance.

Performance knowledge on Hammer Shaft

Performance knowledge on Hammer Shaft includes:

1. Stroke and impact: Understanding how the hammer shaft's design affects the stroke
length, impact force, and overall performance.

2. Speed and frequency: Knowledge of how the hammer shaft's speed and frequency
influence the overall efficiency and effectiveness.

3. Torque and power: Understanding how the hammer shaft's design affects the torque
and power transmission.

4. Vibration and balance: Knowledge of how the hammer shaft's balance and vibration
affect the overall performance, operator comfort, and equipment durability.

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 5. Durability and lifespan: Understanding how the hammer shaft's design, materials, and
maintenance affect its lifespan and durability.

In various applications, such as:

1. Pneumatic and hydraulic hammers: Optimizing hammer shaft performance for

efficient material removal or shaping.
2. Forging and forming equipment: Ensuring precise control over the hammer shaft's
movement and impact for accurate material shaping.
3. Construction and demolition tools: Maximizing hammer shaft performance for
efficient demolition, excavation, or material removal.

CONNECTING ROD
A connecting rod is a vital component in an internal combustion engine or a mechanical
system. Here's a detailed explanation:

Function:

A connecting rod connects the piston to the crankshaft, transferring the up-and-down
motion of the piston to the crankshaft, which converts it into rotary motion.

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Design:

A typical connecting rod consists of:

1. Small end: Attached to the piston pin

2. Big end: Attached to the crankshaft

3. Rod body: The main shaft connecting the small and big ends

4. Bearing: Typically a plain bearing or a roller bearing, allowing smooth rotation and
reduced

Friction

Types:

1. I-beam: A lightweight design with an I-shaped cross-section

2. H-beam: A stronger design with an H-shaped cross-section

3. Forged: A connecting rod made from forged steel for added strength

Materials:

Connecting rods are typically made from:

1. Steel: Forged or machined steel for high strength and durability

2. Aluminum: Lightweight aluminum alloys for reduced weight and increased performance

Purpose:

The connecting rod serves several purposes:

1. Transfers motion: Converts the reciprocating motion of the piston into rotary motion

2. Reduces stress: Helps distribute the forces generated by the piston's motion

3. Maintains efficiency: Minimizes energy loss due to friction and vibration

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 In summary, the connecting rod is a critical component that enables the efficient transfer
of otion and energy in an internal combustion engine or mechanical system.

CAMSHAFT

A Camshaft is a vital component in an internal combustion engine. Here's a detailed

explanation:

Function:

A camshaft converts the reciprocating (up-and-down) motion of the pistons into rotary
motion, which ultimately powers the vehicle or machine.

Design:

A typical camshaft consists of:

1. Main journals: The bearing surfaces that support the camshaft in the engine
block

2. Rod journals: The bearing surfaces where the connecting rods attach

3. Counterweights: Heavy metal weights that balance the crankshaft's rotation

4. Crankpins: The offset pins that convert the piston's motion into rotary motion

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Types:

1. Inline crankshaft: Used in inline engines, where the cylinders are aligned in a straight line

2. V-type crankshaft: Used in V-type engines, where the cylinders are arranged in a V shape

Materials:

camshaft are typically made from:

1. Forged steel: High-strength steel alloys for durability and resistance to wear

2. Cast iron: Strong and durable, often used in diesel engines

Purpose:

The camshaft serves several purposes:

1. Converts motion: Transforms the reciprocating motion of the pistons into rotary motion

2. Transfers power: Delivers the power generated by the engine to the transmission and
ultimately the wheels

3. Maintains balance: Counterweights ensure smooth rotation and balance

Key characteristics:

1. Stroke: The distance the piston travels from top to bottom

2. Bore: The diameter of the cylinder

3. Crank radius: The distance from the camshaft 's centreline to the crankpin

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 CASE STUDY

Hammer shafts are used in various machines across different industries. Here are some
examples:

Construction and Demolition Machines

1. Jackhammers: Hammer shafts are used in jackhammers to break up concrete, asphalt,

and other materials.

2. Pneumatic hammers: Hammer shafts are used in pneumatic hammers for demolition,
excavation, and other construction applications.

3. Hydraulic hammers: Hammer shafts are used in hydraulic hammers for heavy-duty
demolition, excavation, and construction applications.

Metalworking Machines

1. Forging machines: Hammer shafts are used in forging machines to shape and form
metal parts.

2. Machining centres: Hammer shafts are used in machining centers for drilling, milling,
and other machining operations.

3. Metal forming machines: Hammer shafts are used in metal forming machines to form
and shape metal parts.

Drilling and Mining Machines

1. Drilling rigs: Hammer shafts are used in drilling rigs for oil and gas exploration,
mining, and other drilling applications.

2. Pneumatic drills: Hammer shafts are used in pneumatic drills for drilling and blasting
operations.

3. Hydraulic drills: Hammer shafts are used in hydraulic drills for heavy-duty drilling
and blasting operations.

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Agricultural and Forestry Machines

1. Post drivers: Hammer shafts are used in post drivers to drive posts into the ground for
fencing and other agricultural applications.

2. Tree fellers: Hammer shafts are used in tree fellers to fell trees and extract timber.

Other Machines

1. Pile drivers: Hammer shafts are used in pile drivers to drive piles into the ground for
foundation work.

2. Railway maintenance machines: Hammer shafts are used in railway maintenance

machines for track maintenance and repair.

3. Shipbuilding machines: Hammer shafts are used in shipbuilding machines for hull
construction and repair.

When working with a hammer and shaft, here are some essential skills to acquire:

Safety Skills

1. Proper grip: Hold the hammer correctly to avoid accidents.

2. Safety glasses: Wear safety glasses to protect your eyes from debris.

3. Hearing protection: Wear earplugs or earmuffs to protect your hearing.

Technical Skills

1. Measuring and marking: Accurately measure and mark the shaft for precise
hammering.

2. Hammer control: Develop control over the hammer to deliver precise blows.

3. Shaft alignment: Align the shaft correctly to avoid damaging surrounding material.

Physical Skills

1. Strength and endurance: Develop the strength and endurance to handle the hammer
and shaft.

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 2. Hand-eye coordination: Improve your hand-eye coordination to accurately strike the
shaft.

3. Balance and stability: Maintain balance and stability while working with the hammer
and shaft.

Problem-Solving Skills

1. Troubleshooting: Identify and troubleshoot issues with the hammer, shaft, or

surrounding material.

2. Adaptability: Adapt to changing situations and adjust your technique accordingly.

3. Critical thinking: Think critically to solve problems and avoid mistakes.

Other Skills

1. Patience and focus: Develop patience and focus to work accurately and efficiently.

2. Attention to detail: Pay attention to detail to ensure precise workmanship.

3. Tool maintenance: Learn to maintain and care for your tools, including the hammer
and shaft.

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 CASE STUDY

TECHNICAL SKILL OF HAMMER SHAFT Design Skills:

1. CAD design: Ability to design hammer shafts using computer-aided design (CAD)
software.
2. Geometry optimization: Knowledge of how to optimize the geometry of the hammer
shaft for maximum strength and minimum weight.

Manufacturing Skills:
1. 1.Machining: Ability to machine hammer shafts using various machining processes,
such as turning, milling, and grinding.

Analysis Skills:

1. Finite Element Analysis (FEA): Ability to analyze the stress and strain on the hammer
shaft using FEA software.

2. Vibration analysis: Knowledge of how to analyze the vibration of the hammer shaft
and its effects on the overall system.

PERFORMANCE SKILL OF HAMMER SHAFT Mechanical Performance:

1. Torque transmission: Ability to transmit high torque values from the hammer head to
the shaft.

Dynamic Performance:

1. Speed and acceleration: Ability to operate at high speeds and accelerations without
compromising performance.

Endurance Performance:

1. Fatigue life: Ability to withstand repeated loading and unloading cycles without
compromising performance.

Efficiency Performance:

1. Energy efficiency: Ability to minimize energy losses and maximize efficiency during
operation.

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Case Study:

Company: Fitwell Tool and Forging Private limited

Problem: Components Manufacturing Inc., a leading manufacturer of hydraulic hammers,

was experiencing frequent failures of their hammer shafts. The failures resulted in costly
repairs, downtime, and decreased customer satisfaction.

Objectives:

1. Identify the root cause of the hammer shaft failures.

2. Design and develop a new hammer shaft that can withstand the harsh operating
conditions.
3. Improve the overall reliability and performance of the hydraulic hammers.

Methodology:
1. Failure Analysis: Conducted a thorough analysis of the failed hammer shafts to
identify the root cause of the failures.
2. Material Selection: Selected a new material with improved strength, toughness, and
resistance to wear and corrosion.
3. Design Optimization: Optimized the design of the hammer shaft using finite element
analysis (FEA) to minimize stress concentrations and improve durability.
4. Prototyping and Testing: Manufactured and tested prototype hammer shafts to validate
the design and material selection.
Results:
1. Increased Durability: The new hammer shaft design and material selection resulted in
a significant increase in durability, with a 40% reduction in failures.
2. Improved Performance: The optimized design and material selection also resulted in
improved performance, with a 15% increase in hammering efficiency.
3. Cost Savings: The reduction in failures and improved performance resulted in
significant cost savings, with a 25% reduction in maintenance and repair costs.

A case study on hammer shafts is not readily available, but I can provide some insights on
shafts and their failures. In another case, main shaft repairs in wind turbines were
challenging due to the limitations of traditional repair methods like spray welding.

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 However, a company developed two groundbreaking repair solutions, the Weld Overlay
Journal Repair and Roller Burnishing Journal Repair, which extended the component's life
and ensured a more robust integration with upgraded bearings ¹[6). While these cases
don't specifically focus on hammer shafts, they highlight the importance of proper design,
materials, and maintenance in preventing shaft failures. If you're looking for more
information on hammer shafts, I recommend exploring industry reports or research papers
on mechanical engineering or materials science.

Manual Gear Shifter Components:

1. Gearshift Lever: The gearshift lever is the component that the driver uses to select and
change gears.
2. Gear Knob: The gear knob is the component that the driver grasps to operate the
gearshift lever.
3. Shift Linkage: The shift linkage is the component that connects the gearshift lever to
the transmission.

Crankshaft
A crankshaft is a critical component of an internal combustion engine that converts the
up-and-down motion of the pistons into rotational energy.
Functions of a Crankshaft:
1. Converts Reciprocating Motion to Rotational Motion: The crankshaft converts the up-
and-down motion of the pistons into rotational energy, which is then transmitted to the
transmission and eventually to the wheels.
2. Transfers Power: The crankshaft transfers the power generated by the pistons to the
transmission and other engine components.

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