INDUSTRIAL TRAINING REPORT

MPT AMTEK AUTOMOTIVE LTD.

(RING GEAR PRODUCTION)

9th Feb 2015 - 9th Aug 2015

Department of Mechanical Engineering B.M. COLLEGE OF TECHNOLOGY & MANAGEMENT

M.D. UNIVERSITY, ROHTAK (HR)

Submitted by

AMAN KUMAR

Roll No. 11-ME-06

Under the Guidance of

Mr. MANISH KUMAR Mr. MAHENDER SINGH

(Faculty Coordinator) (Production Head) H.O.D, Mechanical Engg. MPT AMTEK AUTOMOTIVE LTD. BMCTM, M.D. University Dharuhera, Rewari

2

MAY -2015

DECLARATION

I hereby declare that the project work entitled “Ring Gear Production” is an authentic record

of my own work carried out at MPT AMTEK AUTO LTD. As requirements of six month

Industrial Training for the award of the degree of B.Tech. At B.M. College Technology &

Management, M.D University, Rohatak under the guidance of Mr. Mahender Singh from 9th Feb

2015 to 9th Aug. 2015.

_______________

Aman Kumar

(11-ME-06)

Date: ____________

Certified that the above statement made by the student is correct to the best of our knowledge and

belief.

Mr. MANISH KUMAR Mr. MAHENDER SINGH

(Faculty Coordinator) (Production Head)

H.O.D, Mechanical Engg. MPT AMTEK AUTOMOTIVE LTD. BMCTM, M.D. University Dharuhera, Rewari

3

ACKNOWLEDGEMENT

Industrial training is an indispensable part of our engineering curriculum. It provides the students

an opportunity to gain experience on the practical applications of their knowledge. My training at

MPT AMTEK AUTO LTD. Dharuhera has been very fruitful. I sure that the hands of

experience I am gaining here will go a long way towards making me a competent engineer.

I would like to start the series of thanks, which might not be covered in this page, with my Industry

Guide Mr. PAWAN TYAGI who always entertained me and clear my doubts in the plant where

the production takes place. Even though he has a busy schedule he never left me, feel alone in the

plant. Mr. PAWAN TYAGI is a Senior Executive Engineer in Plant at MPT AMTEK PVT LTD,

Dharuhera.

I would like to thank production head Mr. MAHENDER SINGH who made me feel encouraged

and confident throughout the training period so that I can do my best in the Industry with ever-

filled confidence and patience.

My training would not be possible without the Human Resources Department of Mpt Amtek Pvt

Ltd. I would like to thank Mr. V S Yadav Hr head.

Last but not the least I would like to thank Mr. Deepak and all experienced engineers for providing

constant encouragement, support and valuable suggestion during the Training.

I hereby also declare that the contents in this report are true to the best of my knowledge.

AMAN KUMAR

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ABSTRACT

I have done my training at “AMTEK MAGNA POWERTRAIN LTD.” On the basis

of what I have learnt in the company I am here by submitting a report. The report is

about the production products of AMTEK MAGNA Powertrain Auto Ltd .It also

include the specification of the products like ring gear specifications etc . A well

planned and properly executed industrial training helps a lot in calculating good

work culture. It is also about the company plant .The main motive of the industrial

training is to understanding the production of the company. The basic idea of the

training is to understand the production of the products made in MPT AMTEK. My

main focus on the production department. My report will also be consisting some

extra relevant information, as this information is the part of the whole procedure.

I hope you will like the Report and will appreciate its’ content and layout and will

find it useful for further study of the Ring Gear as a component. However I have

tried, my best to avoid any sort of errors but as I also belong to the Homo sapiens

species so one can except some errors or faults.

5

TABLE OF CONTENTS

S.NO. TOPIC PAGE NO.

1. ABOUT MPT AMTEK AUTO LTD. 6 - 27

1. Introduction. 6

2. History of the Company 6

3. Company Profile 8

4. Manufacturing Plants 16

5. Customer Profile 20

6. List of Manufactured Parts 26

2. OBJECTIVES OF THE STUDY & LITERATURE REVIEW 28

3. RING GEAR 29 -33

1. Definition 29

2. Production Process 32

3. Ring Gear Manufacture Flowchart 33

4. RING GEAR PRODUCTION LINE 34-73

1. Bending 35

2. Slitting 39

3. Flash Butt Welding 42

4. Trimming 46

5. Normalizing 48

6. Cold Sizing 51

7. CNC Machining 54

8. Quality Gate 1 57

9. Hobbing 59

10. Chamfering 64

11. Washing And Punching 67

12. Induction Hardening And Tempering 68

13. Quality gate 2 72

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1.1 INTRODUCTION.

Amtek is a leading multi-national manufacturer of automotive components and assemblies with

production facilities located strategically across Asia, Europe and USA. The Group’s extensive

manufacturing capabilities encompass Iron and Aluminum Casting, Forging, Machining &

Assemblies.

Amtek Auto Ltd. has established itself amongst the top players in the Indian auto

ancillary industry and has also grown to become one of the largest manufacturers of Forgings,

Castings, Machined Components and Assemblies, which includes Piston Connecting Rod modules

and Gear Shifter Forks and Yokes, Flywheel Ring Gears in the country. Amtek also holds the

distinction of being among the largest manufacturer of Flywheel Ring Gear Assemblies and

Turbocharger Housings in the World. The uptrend in outsourcing by global OEM majors due to

rising cost pressures, the booming domestic Auto industry, particularly the high – growth diesel

engine segment, and Amtek’s aggressive acquisition and expansion strategy have propelled the

Company into a higher growth trajectory.

1.2 HISTORY OF THE COMPANY

The Amtek Group was established in the year 1985 with the incorporation of the Flagship

Company, Amtek Auto Limited. Over the course of next two decades, the group grew rapidly to

emerge as a global frontrunner in the automotive industry through a number of strategic

acquisitions across India, Europe and the USA, production segment rationalization measures. The

current turnover of the group exceeds $ 750 million.

ABOUT MPT AMTEK AUTO LTD. 1

UNIT

7

Amtek Group is a leading international manufacturer of automotive components and assemblies

with production facilities located strategically across North America, Europe & Asia. The Group's

extensive manufacturing capabilities encompass Sub assemblies, Iron, Gravity & Aluminum

Castings, Forgings, Complex Machining & Ring Gears Flywheel Assembly.

AAL entered into a joint venture with Benda Kogyo of Japan to form Benda Amtek in 1997 for

manufacturing of flywheel ring gears located Gurgoan. Later, in 1999 the company entered a JV

with Ateliers de Siccardi to form Amtek Siccardi for manufacturing crankshafts at Manesar. In

2001 the company acquired auto component manufacturing firm Wesman Halverscheidt Forgings.

The same year it also acquired Indusial Auto components Coimbatore (India).

In 2002 the company established an iron casting facility at Bhiwadi. The same year AAL acquired

14.8% equity stake in Ahmednagar Forgings. The next year in 2003 the company acquired an

additional 20% stake in Ahmednagar Forgings.

In 2006 the company formed 50:50 JV with Canada based Magna Power train to commence

manufacturing facility for 2–piece flex plate assemblies for automotive applications. It also

established a new manufacturing facility at Dharuhera (India) the same year.

In order to manufacture fractured connecting rod modules company entered JV with Magna

Powertrain to form MPT Magna India.The company set up another manufacturing facility at

Sanaswadi, Pune for forging, casting and machining in the year of 2007. The same year it acquired

Triplex– Ketlon Group– which was amongst the largest automotive precision machining

companies and it also had presence in UK.

In February 2008, the company formed 50:50 joint venture with American Railcar Industries in

order to diversify by the setting up of the company's Amtek Transportations systems division. In

June 2008 Amtek Transportation Systems became subsidiary of AAL

Amtek acquired Ahmednagar Forgings Limited (AFL) in order to establish a manufacturing

business in Western India, as there were a number of automotive companies which were being

supplied by AFL in that region. On 10 October 2002 the Company acquired 1,183,790 fully paid–

up equity shares of Rs.10 each in AFL, representing 14.8 percent. Of its issued, subscribed and

paid–up equity share capital, at a price of Rs. 34.50 per share from the promoters of AFL, their

friends, relatives and associates. The Company also entered into an agreement with the promoters

of AFL on 10 October 2002 to acquire from them an additional 2,457,660 fully paid equity shares

8

of Rs. 10 each, representing 30.72 percent. Of the issued, subscribed and paid–up capital of AFL,

at a price of Rs. 34.50 per share.

1.3 COMPANY PROFILE

The Amtek Group, headquartered in India, is one of the largest integrated component

manufacturers in India with a strong global presence. It has also become one of the world’s largest

global forging and integrated machining companies. The Group has operations across Forging,

Iron and Aluminium Casting, Machining and Sub-Assemblies. It has world-class facilities across

India, UK, Germany, Brazil, Italy, Mexico, Hungary and US. The Amtek Group is comprised of

the listed corporate entities Amtek Auto, Amtek India, Ahmednagar Forgings, JMT Auto and other

subsidiaries. With the infrastructure and technology platform developed over 25 years, the Group

is well positioned in the Indian Auto and Non-Auto component markets.

FIG No. 1.1 Company Building

9

Magna Powertrain and Amtek Establish a Joint Venture in India Magna Powertrain, an operating unit of Canadianbased

Magna International Inc., and Amtek Auto Limited today signed a joint venture

Agreement to establish a

Manufacturing facility outside of Delhi, India, for two piece

Flex plate assemblies for automotive applications.

Aurora, Ontario, Canada and New Delhi, India, October 31, 2006 — Magna Powertrain, an

operating unit of Canadian based

Magna International Inc., and Amtek Auto

Limited today signed a jointventure

Agreement to establish a manufacturing facility outside of Delhi, India, for two-piece

Flex plate assemblies for automotive applications.

Manufacturing operations of the joint venture are expected to commence late in 2007. The joint

venture will initially export flex plate assemblies entirely to European

Markets, with production to follow for the Indian market. Flex plate assemblies are used in

automobiles with automatic transmission systems.

The 50/50 joint venture between Magna Powertrain and Amtek expands on Amtek’s existing

relationship as a supplier of ring gears to Magna Powertrain’s North American

Operations. The joint venture represents a step forward in the expansion of Amtek’s customer base

and product portfolio, as well as its technological capabilities, and is

Expected to enhance the competitive positions of both Amtek and Magna Powertrain.

Günther Apfalter, President, Magna Powertrain Europe and Asia stated: “For Magna Powertrain

the joint venture is an important first step into the Indian market. Through

The formation of an alliance with Amtek, Magna Powertrain can make use of Amtek’s special

knowhow

In ring gear

Manufacturing and will benefit from the competitive cost level

In India.”

10

Regarding the agreement, John Flintham, CEO Worldwide

Operations of Amtek said: “This joint venture will be another milestone for the Amtek Group and

a step forward in

Expanding its customer base and product portfolio, as well as attaining a technological and

competitive edge in automotive component manufacturing.”

About Amtek

Amtek is market leader in the manufacture of a variety of fully finished automotive components

and assemblies for use in engine/drivetrain, transmission/powertrain and

Suspension systems for the global automotive industry

About Amtek

Amtek is market leader in the manufacture of a variety of fully finished automotive components

and assemblies for use in engine/drivetrain, transmission/powertrain and

Suspension systems for the global automotive industry.

About Magna Powertrain

Magna Powertrain, an operating unit of Magna International Inc., is engaged in the business of

the design, development, manufacture, assembly and supply of powertrain

and drivetrain products (and related devices) such as transaxles, gear boxes, PTO units, transfer

cases, four wheel drive and all-wheel drive units, and a wide variety of

Engine and transmission components, modules and systems for the global automotive industry.

Fig No. 1.2

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MILESTONE

S.NO. YEAR

1. 2012 Started machining facility

2. 2011 Joint venture with South Korean automaker Autech Corporation

to manufacture specialized vehicles

Amtek Auto’s group company––Amtek Defense Technologies––has entered into a Joint Venture Agreement with Enertec

Management.

3. 2010 Joint venture Sumitomo, Japan.

4. 2009 Established to machining facility, Dharuhera.

5. 2008 Joint venture with American Rail Car, USA

6. 2007 Established a new manufacturing facility at Sanaswadi, Pune (India) for Forging, Casting and Machining

7. 2006 Set up a new machining facility at Dharuhera (India)

MPT Magna India Ltd (India) (JV with Magna Powertrain for

manufacturing Fractured Connecting Rod Modules)

Large scale Aluminum High Pressure Die Casting facility at

Ranjangaon, Pune (India)

8. 2005 Acquisition of Hallberg Guss Aluminum, an Aluminium Casting

facility at UK

Took over Zelter GmbH (Germany), one of the largest

manufacturers of Turbo Charger Housing in the world

Amtek Tekfor Automotive Ltd (India) (JV with Neumayer Tekfor

for manufacturing one and two piece flex plates

9. 2004 Acquired UK based Sigmacast Iron Ltd–Set up a Ring Gears facility?

Amtek Gears Inc. (USA)

10. 2003 Took over Letchworth (UK) based GWK Group Ltd., known for

complex machining and high level module assembly

Acquired UK’s largest manufacturer of Ring Gears and

Flywheels? Lloyds Brierly Hill Ltd.

12

11. 2002 Acquired Midwest Mfg, a US based ring gears manufacturer

Ahmednagar Forgings (India) was taken over

Established an Iron Casting facility at Bhiwadi (India)

12. 2001 Acquisition of auto component manufacturing firm, Wesman

Halverscheidt Forgings (India)

Indusial Auto components Coimbatore (India), a fully automated

foundry with machining facilities, was taken over

13. 1999 Amtek Siccardi, Manesar (India) (JV with Ateliers de Siccardi for

Crankshaft manufacturing

14. 1998 A new Machining unit was set up at Gurgaon (India)

15. 1997 Benda Amtek Ltd Gurgaon (India) (JV with Benda Kogyo Japan for

Flywheel Ring Gears manufacturing)

16. 1996 Established a Machining unit at Gurgaon (India)

17. 1993 Initiation of forging operations at Gurgaon, India

18. 1987 Start of manufacturing at the Machining facility based at Sohna, India

Table No. 1.1

Different divisions of the company are:

Amtek Centre of Excellence (ACE)

Amtek Forging Division (AFD)

Amtek Iron Casting Division (AICD)

Amtek Aluminum Casting Division (AACD)

Amtek Automotive Machining Division (AAMD)

Amtek Ring Gear Division(ARGD)

Amtek JVS

13

Business Divisions

Forgings: -

Forging is the process of forming hot / cold metal. The Forging divisions of the group are Baddi

(H.P). Connecting Rods, Crankshafts, Steering Knuckles, Gears shifter Forks, Sector Gears &

Shafts, Stub Axles, Front Impact Beams etc. are some of the products in the Amtek Forging suite.

Castings: -

Casting is the process of forming from molten metal. The Group has facilities for Iron Castings at

Bhiwadi (Rajasthan), Baddi (H.P), Coimbatore (Tamil Nadu) & Tipton (UK). Besides Iron

Castings, Amtek has facilities for Aluminum Castings at Bourne (U.K) and is in the process of

commissioning another Aluminum Casting facility at Ranjangaon (Mah.).

Machining:-

Machining is the term used for a set of metal – cutting processes which are performed on Forgings

and / or Castings to give them the exact shape and size for assembling in the vehicle. The Group

has Machining facilities within India at Gurgaon (Haryana), Sanaswadi (Mah), Manesar &

Dharuhera (both in Haryana), Baddi (H.P), and across the World at Letch worth, Coventry &

Bourne (in U.K) & Hennef (Germany), Stanberry, Bay City & Kellogg (in USA).

Assembly: -

The Assembling activities are carried at Letch worth, Coventry, Gurgaon, Dharuhera, & Hennef

(Germany). The products include Bridge Fork Assemblies, Strut Assemblies, Wheel Corner

Modules, Axle Assemblies, Turbochargers, Piston Cylinder Modules, Spindle Assemblies, and

Fuel Delivery Systems.

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ACHIEVEMENTS

VISION

We aspire to be the most preferred and reliable provider of products & services globally, with an

unflinching commitment towards technological excellence

CORE VALUE • Customer Focus

• Commitment to Excellence

• Openness, Fairness and Trust

• Team Spirit

Amtek Auto recently won the best investor of the year award 2008 – UK Trade & Investment.

Adjudged ‘Best Performing Vendor’Technology group Machine Parts Maruti Suzuki (1994–95)

• TVS Motors Ltd to Amtek Bhopal(2002–03)

• Forging and Casting group from Honda Motor Cycles & Scooters India Ltd to Amtek Bhopal (2005–06)

• Honda Motor Cycles Scooters India Ltd (2005–06 & 2006–07) to Amtek Bhopal

Won ‘Supplier of the Year’ Award

• Prestigious ‘ET– Best Emerging Company of the Year 2006’ at ‘The Economic Times Awards For Corporate Excellence’

Declared ‘ET– Best Emerging Company of the Year’

15

1.3 Manufacturing Plants

Technology and Transcends Boundaries

Thriving on challenges Amtek registered its presence across North America, Europe & Asia to

cater a number of client. And is poised to explore new global frontiers to invent new products

and scale to new heights.

AMTEK WORLDWIDE CENTERS

INDIA

U.S.A

MEXIO

BRAZIL

ITALY

U. K

HUNGARY

GERMANY

FIG No. 1.3 Amtek Map

16

EUROPE

Letchworth (UK) GWK Amtek Machining

Coventry GWK Amtek Machining

Hennef (Germany) - I

- II

Zelter Machining

Zelter Machining

Witham (UK) Amtek Investments

UK Limited

HPDC Aluminium Casting

USA

Bay City (MI) Amtek Gears (Amtek

Inv US)

Ring gears / Flywheel assembly

Kellogg (IN) Midwest Mfg.

(Smith Jones)

Ring gears / Flywheel assembly

Stanberry (MO) Midwest Mfg.

(Smith Jones)

Ring gears / Flywheel

17

AMTEK INDIA

RING GEAR/FLYWHEEL

ASSEMBLY

Gurgaon

Dharuhera

CASTING

Rajangaon

FORGING

Dharuhera

Unit I I

Gurgaon

Bopal

Chakan

Ahmednagar

MACHINIG

Sohna

Gurgaon

Dharuhera

Unit I

Dharuhera

Unit I I

Sanaswadi

Nalagrah

Maneser

Maneser

Chakan

Ahmednagar

18

FIG No.1.4 Amtek across India

19

1.4 CUSTOMER PROFILE

AUTO SECTOR CUSTOMERS

2/3 WHEELERS

20

PASSENGER CARS

21

22

LIGHT COMMERCIAL VEHICAL

23

HEAVY COMMERCIAL VEHICAL

OIHER

24

NON AUTO CUSTOMER

25

1.6 MANUFACTURED PARTS

Product range of the company includes:

Amtek product portfolio consists of an extensive range of components for 2–3 wheelers, Car,

Tractors, LCV, HCV and Stationary engines. The major categories of components manufactured

are,

Connecting Rod Assemblies

Flywheel Ring Gears and Assembly

Steering Knuckles

Suspension and Steering Arms

CV joints

Crankshaft Assemblies

Torque Links.

FIG No.1.5 Manufacture Parts

26

MODEL OF RING GEAR

27

The main objective of the Training is to study the Production process of the Amtek MAGNA

Powertrain Ltd. And to analyses the Production process and defects of the Amtek MAGNA

Powertrain Ltd... The study includes the study of all control plans of the products and machining

processes etc. The main objective in working with the production process is to calculate the

production rates with in time and without any defects.

My duty in company was to understanding and studies the production of Ring gears process. MPT

AMTEK deals with the production or machining of ring gear. It is a joint venture of Amtek group

OBJECTIVES OF THE STUDY & LITERATURE REVIEW 2

UNIT

28

DEFINITION:-

A starter ring gear, sometimes called a starter ring or ring gear, is a medium carbon steel ring

with teeth that is fitted on the periphery of a flex plate or flywheel of an internal combustion engine,

mostly for automotive or aircraft applications. The teeth of the starter ring are driven by the smaller

gear (the pinion) of the starter motor.

The primary function of the starter ring is to transfer torque from the starter motor pinion to the

flywheel or flex plate to rotate the engine to begin the cycle.

Manufacture

The starter ring gear is most commonly made by forming a length of square or rectangular steel

bar into a circle and welding the ends together. There then follow various operations such as

normalising (to remove stresses and improve the properties in the weld area), turning, generating

the teeth by gear hobbing and finally a heat-treatment operation(s). The teeth of the starter ring

need to be hardened in order to increase their strength and resist wear. The normal hardness at

pitch circle diameter is 45-55 HRC. The body of the ring is generally left untreated which gives

some ductility for shrinking onto a flywheel or welding to a flex plate.

Attachment

Engines with manual transmission usually have a heavy flywheel, typically 5 to 10 kg of cast iron,

with the starter ring gear shrunk onto the outside. This is done by heating the ring to around 200

°C to expand the ring which is then placed onto the flywheel, often held in firmly against a location

shoulder until cool. The interference fit renders the starter ring firmly attached to the flywheel. [1]

Engines with automatic transmissions instead have a pressed steel plate with the starter ring gear

usually welded onto the outside of the plate

RING GEAR 3

UNIT

29

FIG No. 3.1 Ring Gear

Fig No. 3.2 Ring Gear Use

30

FIG No. 3.3 Raw Material

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PRODUCTION PROCESS

Ring Gear Manufacturing

1. Blanking: Blanking process the rolling of a straight trapezoidal bar of steel into a coiled form; slitting the entire coil at a point to separate each steel loop of the coil which in the

form of ring but silt at point; flash butt welding together of the separate end of the loop together to form a complete ring; removal of extra welding flash from the ring; tempering

of the welded ring to revealed the stress created in the ring during welding and finally this operation is followed by the shot blasting operation, which is done to remove the scales form during the normalizing operation. After this operation being completed the ring are

press on the hydraulic press to rectify any deformation created during the previous processes. Now the ring is ready for machining.

2. Machining: the machining processes involved is turning. Basically the turning operation on a ring is done in two step. In the first step & the internal diameter is turned to specific

size and surface finish. The cycle time to this operation is varies between 1-1.5 minutes depending on the size of the ring. In the second step outer diameter & outer face is turned

and the cycle time varies between 1 - 1.5

3. Hobbing: The term hobbing is refer to the process of cutting the outer diameter of the machining ring into the shape of gear teeth by a specially designed cutting tool is called

the hob cutter. The profile and the shape of the cutter on the hob. Gera hobbing is performed on special purpose machine called the gear hobber and the fixture on which rings are held during the hobbing process is called the colleted type hobbing fixture which has a highly

intricate design which allow the fixture to contract and expand for the purpose of ring loading and unloading and after hobbing respectively. The cycle time of the operation

varies between 30-45 min.

4. Chamfering: In the chamfering process the sharp edges of the gear teeth on the clutch

side of the gear are removed to facilitate easy engagement of gear teeth with the pinion gear of the electric starter motor of the engine as to avoid any kind of friction, which may

occur otherwise during actual use. The approx. cycle time of the operation is between 50sec -120sec depending on the component.

5. Debarring & washing punching: In the process the loose chips of the metal which may

have stuck of the ring are removed and the gear are washed using antirust oil. This operation take around one minute. Punching of the batch code and the supplier code is alose done after this process.

6. Induction hardening: This is the operation of raising the surface hardness of the gear teeth

up to a specific level and the depth of the hardness is also controlled to achieve a specific case as per the design requirement of the costumer. Immediately after the induction Harding the gear are lowered in the quenching tank which contains any three liquid that is,

32

oil, polymer or water. The cycle time for the operation varies between 20-40sec depending on the size the component and hardness required.

Ring Gear Manufacturing Process

RAW MATERIAL

(Trapizodial Bar Of Alloy Steel)

INWARD INSPECTION

(To Verify The Dimensional And Metallurgical Parameter )

BLANKING

MACHINING

HOBBING

CHAMFERING

WASHING

INDUCTION HARDENING

FINISHED COMPONENT

33

There are several processes on the different machines is involves to produces the ring gear on the

production line. Product and machines have different specification at several processes.

FLOW CHART OF RING GEAR PRODUCTION LINE

RING GEAR PRODUCTION LINE 4

UNIT

RAW MATERIAL (QUALITY

CHECK)

BENDING MACHINE

SLITTING MACHINE

BUTT WELDING MACHINE

TRIMING MACHINE

NORMALIZING

MACHINE

COLD SIZING MACHINE

CNC

MANCHINEQUALITY GATE 1

HOBBING

MACHINE

CHAMFERING MACHINE

PUNCHING

MACHINE

WASHING MACHINE

INDUCTION HARDENING

MACHINE

QUALITY GATE 2

34

1. BENDING:-

Bending Machine is used to bend the square or trapezoidal bar into ring form. The bending m/c has three rollers

A. Upper roller

B. Right roller

C. Left roller

The rod is kept on the left & right roller and then press by the upper roller then move in the

clockwise direction. Then the process operate automatically form the ring shape. There is only

upper roller movement in vertical direction. The specification is given by customer.

The cycle time for bending machine is 15 sec.

The cycle operation is 120 min. Part name NI-XH5 specification Measuring INS

Inner diameter - 237.5-238.5mm VC

Upper roller position - 75±2mm

Vertical Hang Pin Position - 85±2mm

Fig No. 4.1 Bending Machine

35

Fig No. 4.2 Bending Processes

After the bending processes raw material will be produced as shown in fig

Fig No. 4.3 after Bending

36

OK SAMPLE PRODUCT

Fig No. 4.4

DEFECTIVE PRODUCT

Fig No. 4.5

37

Bending Defects:- a. Spring loose

b. Irregular coiling

c. Bending with T1 outside

Fig 4.6 [Defects in bending]

38

2. SLITTING:-

Slitting machine is used to cut the ring coil form in bending machine in different rings.

By pressing the five coils ring and cut into different parts.

Cycle time is 40 sec.

Cycle operation time is 120 min.

Slitting Machine Specification for NI-XH5 Ring gear measuring INS

After cutting diameter - 239-240 mm VC

Overlap - 2 mm minimum VC

Tool change frequency - 200 coils Production

Hydraulic pressure - 35-55 kg/cm³ Pressure gauge

Coolant - cool edge 3-5% Refract meter

Fig No.4.7 Slitting Processes

39

PRODUCT ON SALTTING

Fig No. 4.8 Slatted product

40

Fig No. 4.9 Slitting Machine

41

3. FLASH BUTT WELDING & TRIMMING:-

Flash butt welding is a type of resistance welding without using any filler metal. It is used for

joining two metal parts together using heat and force. Each of the two parts to be joined is clamped

against an electrode, usually a copper alloy. The electrodes themselves being connected to the

secondary side of a transformer. The ends are brought slowly together until they just touch. At this

point a high current flows through the touching points, rapidly heating and melting the metal at

the points of contact. The molten metal is then expelled by its own rapid expansion. This part of

the welding cycle is called the flashing and generally creates a spectacular shower of sparks.

Voltage used is generally low (typically between 4 and 20 volts) but the current usually very high,

often in the tens of thousands of amps. The heat generated raises the temperature of either side of

the joint. Once the temperature is above the forging temperature (typically around 1,250°C for

steel) the ends are rapidly pushed together with great force. The high speed expels any remaining

molten metal and the high force generates enough pressure at the joint (around 90 megapascals for

steel) to 'forge weld' the ends together.

THE DIFFERENT CYCLES USED

Pre-Heating

Sometimes an optional pre-heating operation is used to heat the joint area using Joules energy from

passing a current through the joint area directly without any flashing. This heats the whole area

between the electrodes. Pre-heating itself is sometime preceded by a 'Burn off' cycle which

prepares the ends for better contact in the pre-heating cycle.

Flashing Operation

An important parameter is to attain the proper forging temperature around the joint. This is

generally dependent on the amount of heat generated by the flashing cycle. Flashing is typically

determined by either a pre-set amount of time (seconds) or a pre-set distance to be flashed away

(mm). Whereas pre-heating will heat the whole joint area that is between the electrodes, flashing

will instead generate heat only at the joint interface. Heat will then be conducted back into the joint

parent metal.

Butting a.k.a. upsetting

Once the correct temperature profile has been generated then the ends of the joint are rapidly forced

together. Initially a high velocity 'squirts' out any impure molten metal at the joint interface before

it solidifies. Further movement as the joint cools swells the joint area through an upsetting action

until the pressure at the joint, along with the temperature is sufficient to 'forge-weld' the ends

together.

Hold Time

At the end of upsetting there is commonly a 'hold time' during which the joint is held still to allow

the joint to cool and the two pieces of metal to completely bond.

42

Applications I. Railway Lines (Flash butt welding machines are often transported to the work site on

a road-rail vehicle) II. Chains

III. Steel wheels IV. Sheets or rods of steel in rolling mills. V. Starter rings

Fig No. 4.10 Butt Welding Processes

PARTS OF TRIMMING AND BUTT WELDING:-

I. Flash butt welding and trimming machine

II. Top clamp

III. Electrode

IV. Trimming resting pad

V. Trimming bit

VI. Horizontal cassete

VII. Vertical cassete

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Fig No. 4.11 Flash Butt Welding Machine

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PRODUCT AND MACHINE SPECIFICATION

Specification for NI-XH5 Part

Internal Diameter - 237-238 mm

Welding strength - 542 Nmm² minimum

Ovality - 2 mm max without weld area

Trimming depth on both faces - 0.3 mm max

Trimming depth on ID - 0.3 mm max

Trimming depth on OD - 0.3 mm max

Electrode change after - 1500 pcs

Welding start position - 40±5 mm

Fleshing length - 4±1 mm

Butting length - 4±1 mm

Preheat - off

Free heat pressure - 0

Free heat count - 0.0

Initial fleshing velocity - 3.7±0.20 mm/sec

Initial current feedback - 2.0±0.20 amp

Acceleration - 4.0±1 mm/ sec²

Butting hold time - 1.2±20 sec

Fleshing time - 2±0.50 sec

Clamping pressure - 40±5 kg/cm²

Butting pressure - 30±5 kg/cm²

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4. TRIMMING:-

Trimming is the processes in which unwanted and extra material is removed by the special tool.

After the butt welding extra material is worn out on the welding spot, this is removed by the

trimming and trimming is done by the grinder, trimming machine.

Fig No.4.12 Trimming Machine

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Fig No.4.13 after Trimming

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5. NORMALIZING:-

Importance of Normalizing

A necessary first step in the heat treatment process involves "normalizing," a process

designed to present a homogenous microstructure to the carburizing process. To reduce

overall part distortion, it is highly undesirable to have this homogenization take place during

the carburizing cycle of a finished gear component. A separate normalizing cycle removes

the problems associated with pearlite and ferrite segregation. Ferritic areas do not transform

to the same hardness and stress levels as pearlitic areas when homogenized during the

carburizing cycle, resulting in more--not less--distortion.

Normalizing is a process that involves heating a part above the upper critical temperature and

then typically air cooling outside the furnace to relieve residual stresses in a gear blank and to

aid dimensional stability. Normalizing is often considered from both a thermal and

microstructural standpoint. In the thermal sense, normalizing is austenitizing followed by

cooling in still or slightly agitated air or nitrogen. In a microstructural sense, the areas of the

microstructure that contain about 0.8 % carbon are pearlitic, while the areas of low carbon

are ferrite. A normalized part is very machinable but harder than an annealed part. It also

relieves any residual stresses present from the steel making and forging processes that could

cause later distortion during carburizing.

A good normalizing cycle consists of holding the rough material "at temperature" for two

hours minimum, or one hour per inch of section thickness. The temperature should be the

same or higher than the carburizing temperature later used

PRODUCT AND MACHINE SPECIFICATION

Hardness - 85-95 HRB Grain size - 5-8 ASTM

Micro structure - normalized structure Uniformly distributed ferrite with pearlite

Power level - 24%-28% Heating time - 20-25 sec Min temperature - 800 ·c

Max temperature - 890 ·c

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Fig No. 4.14 (Normalizing Induction Machine)

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Fig No. 4.15 (Normalizing Induction Coil)

Product at the Normalizing Processes

Fig No. 4.16 Normalizing Ring Gear

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6. COLD SIZING:-

Cold sizing is a squeezing operation performed at temperatures significantly below the melting

point to finish the surface of a work piece to ensure better dimensional accuracy and surface

finish.

The sizing operation is a squeezing operation that minimizes the thickness of the metal. Sizing

is performed in an open die and only the surface where the die and work piece touch will be

sized. Many ferrous metal castings are sized to sharpen corners and flatten holes around

piercings. Sizing pressure is determined by area to be sized, the metal used, and the change in

metal thickness from the operation. Sizing is usually performed on semi-finished parts or parts

that require an accurate finish. Stop blocks are used to ensure close tolerances.

Cold sizing, like all other cold forming processes, has a hot process counterpart. In addition to

semi-finished parts, cold forming may be used on metal stock, sheet, bar, and rod stock. Cold

sizing can be performed on various metals, both ferrous and non-ferrous, and even materials

like polymers and plastics. Sizing is related to other squeezing operations like swaging,

coining, hobbing, staking and riveting, thread rolling, and extruding.

Although the whole work piece may be inserted into the die, the sizing operation can give

dimensional accuracy to a portion of the part based on the contact with the die. Sizing is mostly

used to give a forged or cast part better dimensional accuracy. Mated surfaces between

touching parts like gears are often sized. The sizing operation also provides a better surface

hardness and finish to the work piece. Also, the sized surface of the work piece gets denser and

stronger when the operation is performed. The dimensional tolerance of the operation is about

0.025 millimetres (0.00098 in). Primary pressing or a compacting die are typically used when

sizing small batches of compact. To keep costs down, larger batches of compact usually have

a specialized die made specifically for the operation.

Parts of cold sizing machine

Press machine and Core bar

51

Fig No. 4.17 Cold Sizing Machine

52

PRODUCT AND MACHINE SPECIFICATION

Specification for part NI-XH5

Internal diameter - 287.5±0.5 mm at three points

Ovality - 0.40 mm max

Flatness - 0.40 mm max

Trimming depth on both faces - ±0.50 mm

Hydraulic pressure - min 130 kg/cm²

Hold time - 35 sec

Fig No. 4.18 Cold Sized Product

53

7. CNC MACHINE

Definition of CNC

CNC means Computer Numerical Control. This means a computer converts the design

produced by Computer Aided Design software (CAD), into numbers. The numbers can be

considered to be the coordinates of a graph and they control the movement of the cutter. In this

way the computer controls the cutting and shaping of the material.

Processes

Lathes are machines that cut work pieces while they are rotated. CNC lathes are able to make

fast, precision cuts, generally using index able tools and drills. They are particularly effective

for complicated programs to make parts that would be more difficult to make on manual lathes.

CNC lathes have similar control specifications to CNC mills and can often read G-code as well

as the manufacturer's proprietary programming language. CNC lathes generally have 2 axes

(X and Z), but newer models have more axes allowing for more advanced jobs to be machined

Fig No. 4.19 CNC lathe operation

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Fig No. 4.20 CNC lathe machine

ADVANTAGES 1. CNC machines are programmed with a design which can then be manufactured hundreds

or even thousands of times. Each manufactured product will be exactly the same.

2. CNC machines can be updated by improving the software used to drive the machines

3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc.

which need skilled engineers

4. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to

be switched off for occasional maintenance.

5. CNC machines can be programmed by advanced design software such as Pro/DESKTOP®,

enabling the manufacture of products that cannot be made by manual machines, even those

used by skilled designers / engineers.

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6. Modern design software allows the designer to simulate the manufacture of

his/her idea. There is no need to make a prototype or a model. This saves time

and money

DISADVANTAGES

1. CNC machines are more expensive than manually operated machines, although costs are

slowly coming down.

2. The CNC machine operator only needs basic training and skills, enough to supervise

several machines. In years gone by, engineers needed years of training to operate Centre

lathes, milling machines and other manually operated machines. This means many of the

old skills are been lost.

3. Less workers are required to operate CNC machines compared to manually operated

machines. Investment in CNC machines can lead to unemployment

4. Many countries no longer teach pupils / students how to use manually operated lathes /

milling machines etc... Pupils / students no longer develop the detailed skills required by

engineers of the past. These include mathematical and engineering skills

APPLICATION 1. Industries for Fabricating Metals

2. Electrical Discharge Machining (EDM) Industry

Fig No.4.21 CNC Turning

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8. QUALITY GATE 1

Quality inspection is the most important and necessary processes in any production unit. It’s

provided varies information of the product specification, size, quality and dimension. Quality

inspection is help to improve precision and accuracy. It also beneficial to increase the

production rate.

In the quality inspection varies processes involves and this processes is the done under

predefined guidelines. It standardized the product

In the Ring Gear production are the following quality check is to be done:-

1. ID (internal diameter)

2. OD (outer diameter)

3. OVALITY

4. GEAR PROFILE

Fig No. 4.22

57

Fig No. 4.23

Fig No. 4.24

58

9. HOBBING:-

Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a

hobbing machine, which is a special type of milling machine. The teeth or splines are

progressively cut into the work piece by a series of cuts made by a cutting tool called a hob.

Compared to other gear forming processes it is relatively inexpensive but still quite accurate,

thus it is used for a broad range of parts and quantities.

It is the most widely used gear cutting process for creating spur and helical gears and more

gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

A type of skiving that is analogous to the hobbing of external gears can be applied to the cutting

of internal gears, which are skived with a rotary cutter (rather than shaped or broached).

Fig No. 4.25 Hobbing Cutter

Process

Hobbing uses a hobbing machine with two skew spindles, one mounted with a blank workpiece

and the other with the hob. The angle between the hob's spindle and the workpiece's spindle

varies, depending on the type of product being produced. For example, if

59

a spur gear is being produced, then the hob is angled equal to the helix angle of the hob; if a

helical gear is being produced then the angle must be increased by the same amount as the

helix angle of the helical gear. The two shafts are rotated at a proportional ratio, which

determines the number of teeth on the blank; for example, if the gear ratio is 40:1 the hob

rotates 40 times to each turn of the blank, which produces 40 teeth in the blank. Note that the

previous example only holds true for a single threaded hob; if the hob has multiple threads then

the speed ratio must be multiplied by the number of threads on the hob. The hob is then fed up

into workpiece until the correct tooth depth is obtained. Finally the hob is fed through the

workpiece parallel to the blank's axis of rotation.

Up to five teeth can be cut into the workpiece at the same time. Often multiple gears are cut at

the same time for very large gears the blank can be gashed to the rough shape first to make

hobbing easier.

The hob is a cutting tool used to cut the teeth into the workpiece. It is cylindrical in shape with

helical cutting teeth. These teeth have grooves that run the length of the hob, which aid in cutting

and chip removal. There are also special hobs designed for special gears such as the spline and

sprocket gears.

The cross-sectional shape of the hob teeth are almost the same shape as teeth of a rack gear that

would be used with the finished product. There are slight changes to the shape for generating

purposes, such as extending the hob's tooth length to create a clearance in the gear's roots. Each

hob tooth is relieved on the back side to reduce friction.

Most hobs are single-thread hobs, but double-, and triple-thread hobs increase production rates.

The downside is that they are not as accurate as single-thread hobs. Depending on type of gear

teeth to be cut, there are custom made hobs and general purpose hobs. Custom made hobs are

different from other hobs as they are suited to make gears with modified tooth profile. The tooth

profile is modified to add strength and reduce size and gear noise.

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THIS LIST OUTLINES TYPES OF HOBS:

1. Roller chain sprocket hobs

2. Worm wheel hobs

3 .spline hobs

4. Chamfer hobs

5. Spur and helical gear hobs

6. Straight side spline hobs

7. Involute spline hobs

8. Serration hobs

9. Semi topping gear hobs

Fig No. 4.26 Hobbing Diagram

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Fig No. 4.27 HOBBING MACHINE

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PRODUCT AND MACHINE SPECIFICATION

Specification for part Mazda fz2 Measurement of teeth over 14 teeth - 105.39±0.07 mm

MOT variation - 0.10 max Root diameter - 291.95±0.10 mm Gear profile - deflection should not be more than

0.35 mm on dial indicator No. of teeth - 117

Hobb cutter specification Clamping pressure - 30-40 kg/cm²

Axial feed - 1.4-1.9 mm Hob run out - 0.05 max

Fixture run out - 0.04 max RPM of hob - 100-150 Stack height - 11 nos

Fig No. 4.28 after hobbing processes

63

10. CHAMFERRING A chamfer is a transitional edge between two vertices of an object. It can also be known as

a bevel but connotes more often cutting and more often 45°. If the un-chamfered intersection

of the adjoining faces would otherwise form a right angle, 90° as is most common, the chamfer

will typically be uniform and pitched at 45°.

"Chamfer" is a term commonly used in mechanical and manufacturing engineering. Special

tools such as chamfer mills and chamfer planes are available. In tile work, or furniture such as

counters or table tops, an edge or arris that has been eased by rounding instead of chamfering

is called a bullnose. Where a chamfer does not go to the end of the piece, but "lifts out" in a

smooth curve, the end is called a lark's tongue usually seen as a pair in these fields.

Fig No. 4.29

Fig No. 4.30 Chamfering Diagram

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MACHINE PARTS

Chamfering m/c

Chamfer cutter

Fixture

Top plate

PRODUCT AND MACHINE SPECIFICATION

Specifications NI-XH5

Angle side chamfer - opposite side of ID big chamfer side

Chamfer angle - 45±3 degree

Chamfer depth - 5 mm max from root

Chamfer width - 1±0.2 mm

Chamfer tooth form - no deformed teeth

TCF hob cutter - 1500

Hob run out - 0.05mm max

Fixture run out - 0.06 mm max

Fig No. 4.31 Chamfering Machine

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Ring gear after the chamfering processes

Fig No. 4.32 Chamfered Product

Chamfering is not done all the model of the ring gear

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11. PUNCHING AND WASHING

Punching:-

Punching is a metal forming process that uses a punch press to force a tool, called a punch,

through the work piece to create a hole via shearing. The punch often passes through the work

into a die. A scrap slug from the hole is deposited into the die in the process

This is use to punch the batch/lot number on face of ring gear.

WASHING:-

Washing is basically an industrial bath. In this processes ring gear is washed out the industrial

chemical which remove the unwanted material and provide a protection layer to ring gear from

the corrosion.

Fig No. 4.33 Washing Machine

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12. INDUCTION HARDENING AND TEMPERING

INDUCTION HARDENING:-

Induction hardening uses induced heat and rapid cooling (quenching) to increase the hardness

and durability of steel. Induction is a no-contact process that quickly produces intense,

localized and controllable heat. With induction, only the part to be hardened is heated.

Optimizing process parameters such as heating cycles, frequencies and coil and quench design

results in the best possible outcomes.

BENEFITS

Induction hardening boosts throughput. It is an extremely fast and repeatable process that

integrates easily into production lines. With induction it is usual to treat individual workpieces.

This ensures each separate workpiece is hardened to its own precise specifications. The

optimized process parameters for each workpiece can be stored on your servers. Induction

hardening is clean, safe and typically has a small footprint. And because only the part of the

component to be hardened is heated, it is extremely energy-efficient

Fig No. 4.34 Gear at Induction Hardening

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TEMPERING:-

Induction tempering is a heating process that optimizes mechanical properties such as

toughness and ductility in workpieces that have already been hardened.

BENEFITS

The main advantage of induction over furnace tempering is speed. Induction can temper

workpieces in minutes, sometimes even seconds. Furnaces typically take hours. And as

induction tempering is perfect for inline integration, it minimizes the number of components

in process. Induction tempering facilitates quality control of individual workpieces. Integrated

induction temper stations also save valuable floor space.

Fig No. 4.35 Gear at Induction Tempering

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PARTS OF THE MACHINE

Induction hardening and tempering machine

Hardening fixture

Tempering block

Tempering coil

Fig No. 4.36 Induction Hardening and Tempering Machine

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PRODUCT AND MACHINE SPECIFICATION

INDUCTION HARDENING

1. Power S1% - 60-65% 2. S1 time sec - 5-7 3. Power S2% - 60- 70

4. S2 time sec - 4-6 5. Heating dwell time - 00

6. Quenching temperature - 50±3°c 7. Quenching flow in LPM - 200-250 8. Quenching time sec - 25±3

9. Hardening position - 176±10 10. Concentration of polymer - 21-23

11. Polymer checking - cooling crick 12. Fixture forces - 0.2 max

INDUCTION TEMPERING

1. Power % - 5-8 2. Heating time - 5±2 3. Dwell time - 0.5±0.25

Fig No. 4.37 Principle of Induction

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13. QUALITY GATE 2 Quality control, or QC for short, is a process by which entities review the quality of all

factors involved in production. ISO 9000 defines quality control as "A part of quality management focused on fulfilling quality requirements"

This approach places an emphasis on three aspects

1. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, and qualifications 3. Soft elements, such as personnel, integrity, confidence, organizational

culture, motivation, team spirit, and quality relationships.

Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market.

Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example. .

Fig No. 4.38

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Fig No. 4.39

73