REPORT ON

AT FORCE MOTOR PITHAMPUR (M.P.) BODY SHOP

DURING THE PERIOD OF

INDUSTRIAL SUMMER TRANING

13/05/13

TO

12/06/13

Under the supervision of:

Submitted to:

Prepared By:

MOHIT CHATURVEDI

A.V SHITHOLE

MANOJ (A.M.Traning centre)

KUMAR RAJPUT ( sinior engg.Body shop) (Summer trainee)

Department of MECHENICAL ENGINEERING FROM MANIT BHOPAL, M.P.

REPORT ON
INDUSTRIAL SUMMER TRANING

AT FORCE MOTOR PITHAMPUR (M.P.) BODY SHOP DURING THE PERIOD OF 13/05/13 TO 12/06/13

Under the supervision of: Prepared By:

Submitted to:

MOHIT CHATURVEDI Sanjay pathod (sinior engg. Body shop ) (Summer trainee)

A.V SHITHOLE (A.M.Traning centre)

AKNOWLEDGEMENT
Any project is the fruitful outcome of the hardwork of many. Through this document I would like to express my gratitude toward those whose support and co-ordination have been an essential ingradient of this project. Firstly I would like to thank Mr. S.K. Dutt,sr. Div. ManagerPerssonel, Force Motors Pithampur, and Mr. A. V. Shithole

training officer Force Motors Pithampur for giving me a chance to undergo training in the workshop. I would like to special thanks Mr. G.D. Tripati Gen. Manager Body Shop, Mr. Mohit chaturvedi for the sincere guidance in my project. I am thankful to them for their continuedguidance and support along with their vast pool of knowledge, which was the essential for completion of this project. Alongthe way, I was also ably supported and guided staffs and employees specially by Mr. Vivek prakash Misra , Mrs. Sibil Simol, Mr.Dhananjay pathak,Mr. Pawan Kumar . And like I would mention that the help is even more credible, considering that the workload of staffs was immence. We value our other trainee friends who maintained an educational and friendly environment in the workshop which has its importance in the completion of this training. Finally we thank our parents and all the persons who are directly or indirectly connected to us during the training and supported us throughout to complete the training by constant effort.

BODY SHOP
DEFINATION: (BODY)

n wheeled or tracked vehicles, body roll is a reference to the load transfer of a vehicle towards the outside of a turn. When a vehicle is fitted with a suspension package, it works to keep the wheels or tracks in contact with the road,

providing grip for the driver of vehicle to control its direction. This suspension is compliant to some degree, allowing the vehicle body, which sits upon the suspension, to lean in the direction of the perceived centrifugal force acting upon the car. Anti-roll bars are a part of the suspension specifically designed to address body roll. When a vehicle is fitted with a suspension there is compliance between the mass of the vehicle and the vehicle's contact with the ground. Body roll is the noticeable (either perceived or measurable) deflection produced when load transfer acts on the compliant elements of the suspension. Antiroll bars directly impact body roll but their design intent is actually as a tool to adjust roll couple percentage or roll moment distribution.

There are mainly three lines in body shop:

TRAVELLER TRAX L-CAB

FORCE ONE chessis also assembled

Models of traveller: .3050 WB .CHELLENGER .3350WB .GURKHA .3700WB .4022WB

Models of trax: .CRUISER .TOOFAN .GAMA .KARGO KING

Here we are describing about T1 body consrtuction.whole process goes through following steps

FLOWCHART OF TRAVELLER (T1) BODY CONSTRUCTION

Frame assly Long+cross member Long member assly Frame sub assly

Front panel Assly Cowl assly Steel weld (CNC) Frame+floor

Cab +rear door assly Side wall (SPM) assly Roof assly

Body finishing line KARMANN body assly Side wall+roof

1-Frame sub assembly:

All small part of cross member 1,2,3, 4D,5 .. acording to models length join together by welding. Many brackets like

mounting, spring, torsional etc maked here by small piece welded. consol constructed for front body mounting. Many reininforcement parts attached in sub frame members for strength.

2-Long member assembly:

Front middle and rear long members joined by co 2 n spot welding. After this if we welded inner and outer part of long member according to frame profile. frame mostly frame are made of followinf steel section
Channel section Box section Tubuler section

Channel

box

tubuler

Aerodynamic concept take in consideration for long member assly . so front part keep narrrow , middle portion of two conjugate long member keep sufficient width to provide bigger space in body , rear part greater width than front. For safty and strengh purpose reininforcement metal parts attatched inside long member & bw joint.top head attatched for inner ,outer part tightly fitting.

3-Frame assembly:
Frame or under body is the main part of the chessis, on which the remaning parts of the chassis are mounted. It is a rigid structure that forms a skelton to hold all the major parts

together.generaly engine is mounted in forward end of frame and form a complete power assembly. At the rear end of the frame ,rear axle housing attached through rear spring. Frame are jointed together either riveting or welding, riveted joint can sustain more stress and shock than welding. Frame consist long member,croos members(front, middle ,rear), console ,body mounting brackets for body attached, spring bracket for suspension,fuel tank bracket for fuel tank attach.one suporting cross member for body support. Some design x- member also used .this concentrate stress at centre.

cross member

Longmembers

4-Front panel assembly:

Front panel made of following major parts
LHD fire wall Cover plate assly for column

 Column RH/LH Console lower RH/LH Wind screen Panel upper on wind screen

Fire wall separate inside body to outer envirement.it prevent noise and dust to penetrate in inside body so it also called partition Column joined front frame to roof and keep bounded whole front panel. Cab door hinz in it supported by upper panel. Canal and deshboard mounted on front panel for inside controlling electonics parts A structure cover front panel down portion in this space radiator and engine part mounted. Front lights ,bonet,sidefender all this mounted on structutre.

5-steel weld (CNC): {FRAME+ FLOOR}

It is a special purpose machine (SPM) machine.There is spot welding in steel weld. which is TPM

Here using two CNC welding machine.

SMALL STEEL WELD BTP00359 BIG STEEL WELD- BTP00358

SMALL STEEL WELDThis use only for floor assembly and rear wheel box assly. front floor welded with bulk head which cover rediator .basically floor

have three portion front section,middle section, rear floor section .these three welded by spot gun makes complete floor. There is platform Called shuttel which use for floor transport to work station. The shuttel has two copper plates which act as electrode for spot welding.the machine has four spot welding gun,two spot weldig gun can move in transverse horizontal plane to weld the middle floor to front and rear floor.other two gun weld the rear wleel boxes(RH&LH) to the floor.

BIG STEEL WELDBig steel weld machine weld the floor to the frame. in big steel

weld shuttel can move along machine(horizontal) and verticle. There is two station in big steel weld namely 120 & 130. Shuttel has copper plates which act as one electrode of spot welding. 120 station- 120 station has two spot spot welding gun which can move along a inclined plane to weld the front inclined part of roof to frame.at 120 station gun make 95 spots. 130 station- 130 station has two spot welding gun which can move along horizontal plane to weld the middle and rear portion of floor to frame. both welding gun in 130 station can spot two points at a time acording to cnc programming. This station make aprox 162, 192,212,&306 no. of spots for traveller 3050,3350,3700 &,4022 respectively.

6. cowl assembly:
this station mainly +frame+structure. assembled front panel+ floor

Cowl term use globally as Head of vehicle .front portion which are with floor is cowl .we can say in hindi MUKHOTA.COWL consist following body part 1-Front panel 2- structure 3-fire wall

4-desboard panel.it has different warnig and indicating devices required to operate the car. 5-canal for air duct hinz 6-wind screen, 7-column for cabin door

Cowl assembly is normally welded to rocker panels and floor pan.the assembly is also made use for supporting the accessories like windshield,wiper,steering etc

7-cab & rear door assembly:

Door has two mainly parts inner cover,outer cover. Front door attached utility assesories like locking system, glass screw lever, lock buttun.inner part cover by panel for asthetic. Front door hinge either front column or column B acording to vehicle design.but travller hinz in front column. Rear door assembled at KARMANN (SPM) assly same as front door.rear door hinged at corner panel.

8-Side wall assembly:

Side wall made of three sub parts called front ,middle ,rear side wall. A corner panel welded at back portion for back light indicator.a rear supporter welded on rear wheel A roof rail attached upper portion on side wall for welding of side wall+roof and absorb torsional stress which exerted by roof bending wrt floor. It also use as chanel for water flow.

9-Roof assembly:

Three pallet of roof -front , middle& rear are welded to make complete roof. Middle portion may be two or three pallets depend on traveller model. There is a special automed machine to weld the front,middle & rear part of roof.in the machine a copper plate act as electrode& inside a other electrode of spot welding gun.

10-Karmann body assembly:

This is SPM type machine.karmann used here only for T1 model. Karmann has two stages, at first stage side walls are welded to the body & at second stage roof is welded to the body.cant rail, column b, coloumn c,corner panel etc attached to the side wall stage. After this manualy some cover plate and reininforcement welded for smothing inside,girder support attached for strengthning. Second stage roof assembled with side wall through roof rail so that torsional stress can sustain.

11-Body finishing line:

Some Componants attached to the body in finishing line .process done in following stepsST NO.1 > Front & rear door & Fender fitment: to hinge the doors to the body. Fenders: these are the side walls on structure on both side. ST NO.2 > Seat box,door setting,Bonnet fitting: bonnet is to cover up the engine hood. ST NO.3 > CO2 welding: first check corner and joint not left welded.then co2 welding apply On remaining points ST NO.4> Grinding: this is a machining process by which excess material on welded points Removed. ST NO.5> Denting and final finishing: manualy or machine. any dent removed by

ST NO.6> Cleaning & buffing: in buffing super finishing process done by sander on grinded Area and scratches area to make body smooth. ST NO.7> Final inspection: inspect whole body to avoid physically ,structural error and Convey to paint shop.

CHASSIS LINE:

Definition Chassis Frame Construction Chassis Strengthening and Crossmembers Nuts Bolts and Fasteners TRAX CHESSIS FORCE ONE CHESSIS

DEFINITION:All Street Rods must have a chassis. A chassis is defined as a structural unit that will support the full load of the vehicle drive train, body and all ancillary components. The body and chassis are detachable by means of standard fasteners and the chassis must not rely on the body for strength. A number that identifies the chassis must be stamped on the chassis. 2.1.2 A Street Rod chassis needs to be a platform that resists twisting. A torsionally rigid chassis will not only be stronger and last longer, but will also provide better handling and allow closer fit-up of body panels. So Chassis is a main

structure of the vehicle on which majar component are mounted which necessary to propel the vehicle.

CHASSIS FRAME CONSTRUCTION :1. The minimum requirement for a chassis that will support a light bodied vehicle (TBucket, Anglia etc) is 75 x 50 x 3mm rectangular hollow section (RHS) mild steel. 2 .The minimum requirement for a chassis that will support heavier vehicles, such as an A model or later Ford, is 100 x 50 x 3mm RHS steel tubing, or tubing of a cross section no less than the original production chassis. 3 .Space frame and other chassis designs are permitted provided that an engineers report is produced if requested by the Examiner. Where there is any concern about the strength or integrity of a chassis, the Examiner may request an engineers report addressing the concern. 4 .All Street Rods must be fitted with a tailshaft loop to contain the tailshaft in the event of front yoke failure. A tailsha ft loop should be positioned no more than 150mm from the front yoke and be constructed so that it will withstand the force of a errant tailshaft that has broken free. The tailshaft loop may be formed as part of the centre crossmember. 5 .Chassis stepped in at the rear to accommodate wheel rims wider than 10 are not permitted.

CHASSIS STRENGTHENING AND CROSSMEMBERS :-

1.he addition of partial or full boxing, lamination of side rails, and the addition of space frame attachments are all suitable means of chassis side rail strength improvement. Full length boxing is highly recommended on all C-section chassis. An Engineers report may be required if a C-section chassis is not boxed. 2. The modification of an early model chassis often includes the full or partial removal of original crossmembers. The minimum requirement after removal of an original crossmember is to install a K member. 3 .All crossmembers must have a minimum wall thickness of 3mm with an appropriate cross-section. The preferred size is 75 x 50mm RHS if one layer is used, or 50 x 25mm or round tube of at least 37mm diameter if two layers are used with ties between the upper and lower layer in appropriate locations. 4 .Chassis crossmembers for engine and drivetrain location may be removable if desired. Ensure that flange plates and bolts used are suitably sized, and that nuts or threaded bosses have enough thread depth for the application. 5 .Any centre crossmember needs to tie together both side rails to ensure torsional rigidity.Refer to the diagrams at the end of the section to ensure that your chassis will be sufficiently rigid. Vintage chassis were not designed as a rigid platform and allowed the chassis and body to flex independently. This is undesirable in a street rod as damage to paint finishes will result from flexing, and ride comfort and safety will be reduced. 6 .Spacer tubes, crush tubes, or stepped bolts must be used wherever a bolt passes through a hollow section of the chassis. The tube should be 3mm or larger wall thickness and welded in position.

NUTS BOLTS AND FASTENERS:1. Tabled below are the minimum standards acceptable for the choice of nuts and bolts used in Street Rods. 1.1 Ungraded bolts - Panel fixing,floor panel fixing, and lightly loaded brackets. 1.2 Grade 3 bolts - Seat belts. 1.3 Grade 5 bolts - Moderately loaded members, suspension mounts, crossmembers and tailshafts. 1.4 Grade 8 bolts - Brake callipers, master and slave cylinder mounts, steering arms and all heavily loaded assemblies. Note that high grade bolts are not to be used as seat belt bolts. It is a requirement that only bolts designed specifically for seat belts be used in this application. 2. Stainless steel bolts are not to be used In high load or stressed situations as they do not possess high tensile strength. It is recommended that these bolts be used in locations where the use of ungraded bolts is permitted. 3. The bolt or fastener should be long enough to ensure that at least one clear turn of thread is visible. This applies to all nuts, including nyloc and locking nuts. 4. Locking devices must

be fitted to all fasteners. These devices include: Spring and shakeproof washers. Nyloc nuts. Deformed thread locknuts or Huck nuts. Castellated nuts with split or roll pins. Lockwire. Split pins. Locking Tabs, and staking.

Trax chassis:
There is a fixture on which component of chassis are fixed and welded by CO2 (MAG) welding. After this chassis is brought on another fixture for full welding because there are not some accessible point on main fixture. Main component of chassis frame:
Long member (RH/LH) Cross member: there are 6 cross member in TRAX chassis

frame. 1st & 6th cross members are front and rear cross members respectively 2nd cross member support the defferential. 3rd cross member support the propeller shaft. 4th cross member is to attatch the dampers at rear.
Body mounting brackets: these are provide to bolt the

body on the chassis. There are 8 body mounting brackets on each side(RH/LH)

 Tale lamp: this is for rear lighting & no. plate attatching. Fuel tank brackets: these are to bolt the fuel tank at middle

(LH)
Upper & lower control arm: these are the part of front

independent suspention.
Engine mounting brackets: to mount the engine on the

chassis.
Leaf spring supports for the rear suspention. Damper attatching link at front. Torsional bar : this acts as a spring for front suspension. Towing brackets at front and rear.

Force one chassis:

In force one chassis, front suspension system is independent suspension using coil spring & rear suspension is rigid axel suspension using coil spring and trailing arm. Main component of Force one chassis frame:
Long members: front(RH/LH)

Middle(RH/LH) Rear(RH/LH)

 Cross members: there are 7 cross members in Force

one chassis frame. 1st & 7th cross members are fitted at front and rear respectively. 2nd & 3rd cross members are given to bolt the lower control arm of front Independent suspension. 4th cross member support the propeller shaft. Remaining cross members make the frame strong.
Body mounting brackets: to mounting the body on

chassis, there are 6 Brackets on each side.

Stearing gear box mounting. Coil spring mounting, to attatch the coil spring in the

suspension at Front and rear.

Trailing arm brackets, hinge the trailing arm to the

frame for rear Suspension.

Fuel tank mountings, fuel tank is mounted at LH

middle.
Foot step brackets, there are 3 brackets at each

side(RH/LH)

Traveller 26(t2)
Monocoque body from pressed steel panels with outstanding structural strenth and unmatched durability. The only vehicle in its category with CED painting. The sidh generation dip painting plant ensures higher level of rust protection. 2X2 Seating arrangement. Equiped with the most advanced G-32 , 5 speed Mercedese licenced shynchromesh gear box low friction, long life and smooth transmission.

Special clutch lining designed for frequent start-stop operation.

Force one technical specification

ENGINE
Engine name Engine type ,intercooler Displacement (cc) Max.Power in KW Max. Torque in Nm Fuel system Emission status Transmission type Gears 2.2FMTECH 4 cyl. in line DOHC 16 valve ,turbo 2149 104 321 common rail diesel injection BS-IV G-32/5,synchromesh with dual fly wheel 5 Forward, 1 Reverse

AXLE
Type Front non driven stub axle

Rear , driven, full floating type axle

SUSPENSION
Front coil spring Rear spring Shoch absorbers(front& rear) absorber Anti roll bar independent double wishbone with multilink with pan hard rod & coil gas charged telescopic shoch on both front and rear

STEERING
Steering type assisted,collapsible& tiltable rack & pinion, power With protaction guard

CLUTCH
Clutch size and type type 240mm dia. hydraulic operated single plate dry

BRAKES
Type withLCRV Font piston calliper Rear Parking hydraulic vaccum assisted ventilated disc with twin pot 4 drum with auto adjuster mechanical linkage type

TYRES & WHEELS

Tyres Wheels 235/70 R16 Tubeless tyres 16,, alloy wheel

CHASSIS
Type of chassis C in C ladder type

PERFORMANCE
Ride and handling fine tuned by Lotus Engg. UK

EXTERIOR DIMENTIONS
overall Length*Width*Hight (mm) Wheel base(mm) Ground clearence(mm) Fuel tank capacity (litres) Turning radius (meters) Kerb weight (kgs) 4860*1780*1885 3025 205 70 6.0 1860

Project report on body shop

subtopics:

Body defination traveller line

traveller 26 trax line

intro

welding processes chessis line {defination, construction, nuts

& bolts &fastener,specification,trax chessis,force one chessis}

force one technical specification

DECLARATION
I undersigned, student of MANIT BHOPAL (M.P.), Here by declare that study of body shop and its effectiveness is a result of my own work and will be purely utilized for academic purpose only.

Date place RAJPUT MANOJ KUMAR

CONTENTS
INTRODUCTION HERITAGE FORCE OVERSEAS PRESENCE IMPORTANT ACHIVEMENTS RESEARCH & DEVELOPMENTS MANUFACTURING PROCESS BODY SHOP CONCLUSION

DECLARATION
I undersigned, student of MANIT BHOPAL (M.P.), Here by declare that study of body shop and its effectiveness is a result of my own work and will be purely utilized for academic purpose only.

Date place PATHOD SANJAY

.
.

2011

Force motors launched its first offering in the personal vehicals segment, the FORCE ONE

2012

Force motors introduces a revolutionary passenger vehical, TRAVELLER 26.

CONCLUSION
The vocational training enhanced our practical knowledge. Most importantly, we were oriented to the industrial scenario and many challenges and subtleties. The smooth functioning of an industry is depends to a large extent on the mutual cooperation among the different wings. We learnt about the function of different parts of an automobile and the importance of man, machine, method and material in the production system of vehicle. Nevertheless, we did enjoy the training to the fullest and are very sure that this training will help us in our future endeavours.

Thanking You