Summer training project report anurag
- 1. Name – Anurag mishra ) Govt. Polytechnic - Manesar Summer Training Report ( On Ring Gear Manufacturing Process )
- 2. Acknowledgement Every project big or small is successful largely due to the effort of a number of Wonderful people who have always given their valuable advice or lent a helping hand. I sincerely appreciate the inspiration, support and guidance of all those people who have been instrumental in making this project a success. I, Anurag, student of Government Polytechnic Manesar (Mechanical Engineering), am extremely greatful to “Amtek Ring Gear -Gurgaon” for the Confidence bestowed in me and entrusting my project. At this juncture I feel deeply honoured in expressing my sincere thanks to Mr. Jitender Mishra, Manager (Engineering & Development) for making the resources available at the right time and providing valuable insights leading to the successful Completion of my project. I express my gratitude to the entire Production & QA team, especially Mr. Vibhu Tyagi, Mr. Jaswant and Mr. Rajiv Dixit for patiently teaching me the office procedures and guided me through the entire project. I am very grateful to the HR Department, especially Mr. Prashant for providing me this opportunity to work in this prestigious Organization. 2
- 3. Contents 3 About the Company List of Customers About The Product Manufacturing PFD Process Introduction IN-House Testing And Checking Facilities
- 4. ABOUT THE AMTEK GROUP 4 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, Japan, Thailand, Germany, Hungary, Italy, Romania, UK, Brazil, Mexico and US. The Amtek Group is comprised of corporate entities Amtek Auto, JMT Auto, Amtek Global Technologies and other subsidiaries and associates. With the infrastructure and technology platform developed over 25 years, the Group is well positioned in the Indian Auto and Non-Auto component markets.
- 5. AMTEK GROUP OVERVIEW - SNAPSHOT 5 Founded 1987 Business Global engineering company with operations across Forging, Iron and Aluminium Casting, Machining and Sub-Assemblies Segments Auto and Non- Auto Manufacturing Facilities 65 world-class facilities across India, UK, Germany, Hungary, Italy, Russia, US, Brazil and Mexico Key Customers BorgWarner, BMW, Caterpillar, CNH America, Cummins, Fiat, Ford, GM, Halliburton, Hero, Honda, JCB, JLR, Maruti Suzuki, Tata, Timken and Volkswagen Listed Subsidiaries Amtek Auto, Amtek India, Ahmednagar Forgings and JMT Auto
- 6. AMTEK CUSTOMERS 6 2/3 Wheelers Passenger Cars Light Commercial Vehicle Heavy Commercial Vehicle Others Auto Sector Tractors Railways Others Non - Auto Sector
- 7. AMTEK – ARGL ( RING GEAR DIVISION ) 7 Highlights • Significant presence near the OEM’s in India & abroad. • Units specialised with wide range of Ring Gears for passenger cars, trucks, buses, tractors & stationary engines • All units adopt the TQM approach on quality. Indicative Product Range •Rolled Ring • Starter Ring Gear Ring Gear Ring Gear • •O •n quality.
- 8. ARGL – MANUFACTURING PROCESS RING GEAR 8 RAW MATERIAL BENDING SLITTING WELDING HOBBING ID TURNING OD TURNING COLD SIZING FINAL GEARWASHING HARDENING TEMPERING DE-BURRING & PUNCHING NORMALIZING CHAMFERING
- 9. ARGL – MANUFACTURING PROCESS ( MACHINING) 9 Ring Blank Shot Blasting Cold Sizing OD Turning Ind. Hardening Tempering De - burring Ring Gear Washing Chamfering Hobbing ID Turning
- 10. 10 RAW MATERIAL Material SAE 1035 – 1050 SAE 4140 S45C, S48C XC- 38 BS 970080ZA74 Size (Range) Section: 8 X 11 (min) 28 X 28 (max)
- 11. 11 BENDING PROCESS In this Process use Trapezodial section Bar feed in Machine and make straight to coil form with help of three Rollers. Given as below. Note:- Bar Feeding Position should be as per given sketch because at the time of bending process material flow direction is Outer Dia to Inner Dia. Straight Bar convert in Coil form after this Process
- 12. 12 SLITTING PROCESS Make regular spring coil to single part with help of cutter .
- 13. 13 WELDING PROCESS – Flash Butt Welding In this Slitted Ring joint with help of Flash Butt welding machine. No extra material to be used for Ring joint . Main Tool use for Welding is copper Electrode .
- 14. 14 NORMALING PROCESS Normalizing Heat Treatment process is heating steel above the critical temperature, holding for a period of time long enough for transformation to occur, and air cooling. Normalized heat treatment establishes a more uniform carbide size and distribution which facilitates later heat treatment operations and produces a more uniform final product. Main product characteristics is 1)Hardness (80 to 96 HRB) 1)Gain Size (5 ~ 8) Product Characteristics :-
- 15. 15 COLD SIZING PROCESS After Welding & Normalising process Part Inner Diameter not in regular shape and parts got excess ovality and Flatness. In cold sizing process use Hydraulic press and round core bar die to correct the excess part ovality and flatness.
- 16. 16 TURNING PROCESS At this process remove the extra material and maintained the required specification. This process done with help of CNC Turning Machine.
- 17. 17 GEAR CUTTING PROCESS This the Main process and critical in Gear manufacturing. Cutting gear teeth in turn blank with help of Hob cutter . Brief detail given on next slide.
- 18. 18 GEAR CUTTING PROCESS Hob Cutter
- 19. 19 TOOTH CHAMFERING Gear Tooth Chamfering process used for mainly smooth engaging between Gear and Pinion. Chamfer cutter use for cutting the chamfer and it’s same as Hob cutter.
- 20. 20 WASHING PROCESS During Gear Cutting & Chamfering process many chips , dust & oil stick on the Parts. It is harmful in Induction Hardening Process, Because all metal particles mix with Quench oil. Washing process use to clean all sticky particles and Oil.
- 21. 21 INDUCTION HARDENING PROCESS This Process use to reduce the wear properties of Gear. It is very critical process. At Hardening process main parameter is power and time .because Hardness of gear teeth depend on power and time combination. Hardness checking is a destructive test that’s why this process is critical . Mainly hardness maintain in Starter Ring Gear is 48 HRC to 55 HRC.
- 22. 22 TEMPERING PROCESS This Process use to reduce the excess stress on material which is occur during Induction Hardening process. This is also called “Stress Release Process” In This process parts kept in closed Furnace for a particular time & temperature. for example 220º C & 40 Minutes. Temperature and Time depend the on the material grade and Hardness.
- 23. 23 DE-BURRING & PUNCHING PROCESS DE-BURRING :- During the Gear Cutting and chamfering process burr occur on gear face due to cutting feed. When tool start the cutting action and complete the cycle it always produce burr on second face . Those burr remove with help of Emery belt.
- 24. 24 DE-BURRING & PUNCHING PROCESS PUNCHING :- Punching process is done for only traceability of parts. This process done with help of Pneumatic Press. Punching detail give as below.
- 25. 25 IN-HOUSE TESTING AND CHECKING FACILITIES Magnetic particle Inspection. Micro Vickers hardness Testers, Shadowgraph, Contour tracer Surface finish tester Spectrometer Carbon Sulphur apparatus UTM, Tooth Drop ball Testing, Microscope for Micro Structure Checking,
- 26. Hofler Lead & Profile testing machine for gears up to dia of 450mm. Carl Zeiss CMM with Gear Analyzing software IN-HOUSE TESTING AND CHECKING FACILITIES
- 27. 11/02/16 27 Testing Infrastructure Standard Room Metallurgy Lab Testing Instruments Calibration Hardness Tester Vickers Rockwell Hardness Tester Microscope Dial Calibration Master Micrometer Callibration Master Height Master IN-HOUSE TESTING AND CHECKING FACILITIES
- 28. 28 THANK YOU