How automatic gear box works

Classification

rear wheel drive

Front wheel drive

Introduction

PROJECT INDEX1.SELECTION OF PROJECT

2.DEFINITION OF PROJECT

3.ANALYSIS OF PROBLEM

4.CAUSE AND EFFECT ANALYSIS

5.DEVELOPMENT OF SOLUTION

6.REGULAR IMPLEMENTATION

7.CONCLUSION

SELECTION OF PROJECT TO REDUCE BORE UNCLEAR REJECTIONS IN

SMALL END OF THE CONNECTING ROD

PART NAME:CONNECTING ROD

COMPONENT:BACR13

DEFINITION OF CONNECTING ROD A rod connecting two moving parts in a mechanism

, especially that between piston and the crank shaft in an engine or pump.

BIG END

STEM

SMALL END

ANALYSIS OF PROBLEMRAW MATERIAL SPECIFICATION :

TEST METHOD=158811-1998

EQUIPMENT=OPTICAL EMISSION SPECTROMETER

CHEMICAL COMPOSITON

ELEMENT MIN. MAX.

CO 0.19 0.22

Mn 0.6 0.85

Si 0.15 0.35

S _ 0.03

P _ 0.03

Cr 0.9 1.2

Ni _ 0.2

Mo 0.17 0.3

Al _ 0.025

HARDNESS=230BHN Max.

BENDING THICKNESS=40microns Max.

ANALYSIS OF PROBLEMPARAMETERS TO BE MAINTAINED IN CONNECTING ROD:

PITCH DISTANCE

PERPENDICULARITY OR SQUARENESS

OVALITY

SURFACE FINISH

WALL THICKNESS

BIG END TAPER , OVALITY , BORE UNCLEAR

SMALL END TAPER , OVALITY , BORE UNCLEAR

SURFACE FINISH , PERPENDICULARITY , PITCH DISTANCE

DEFINITION OF PROBLEM SETTING OBJECTIVES

P-PRODUCTIVITY TO BE IMPROVED

Q-REJECTION PERCENTAGE TO BE REDUCED

C-OPERATIONAL COST TO BE REDUCED

D-ON TIME DELIVERY TO BE ACHIVED

GOAL SETTING

ACTUAL

TARGET

BORE UNCLEAR REJECTION IN 3 MONTHS

PROCESS FLOWCHART OF CONNECTING ROD

RAW

MATERIALFORGING

INWARD

INSPECTION

SMALL END

DRILLING

BIG END

ROUGH

BORING AND

CHAMFERING

INDUCTION

SOFTENING

SHOT

BLSTINGTEMPERING

CASE

HARDNING

OIL HOLE

DRILLING

2ND

SIDE

CHAMFERING

SYMMETRY

INSP.AND

CORRECTION

FINISH

GRINDING

BOTH SIDES

BIG

END&SMALL

END HARD

BORING

OIL HOLE

DEBURGRING

SMALL END

CHAMFERINGBIG END

HONNING

BIG END BORE

INSPECTION

SMALL END

BORE

INSPECTION

VISUAL

INSPECTION

CD,BEND&TWI

ST

INSPECTION&

CORRECTION

CLEANINGSMALL END

HONNING

BIG END

MARKING

SAMPLING

INSPECTIONPACKIMG

BAJAJ AUTO

LTD.

SMALL END DRILLING

SANSERA VERTICAL MACHINING(SVM)

SANSERA HORIZONTAL DRILLING MACHINING(SHD)

DRILLING OF OIL HOLE DONE HERE FOR OIL FLOW

CASE HARDENING

TEMPERING

SHOT BLASTING

INDUCTION SOFTNING

SYMMETRY CORRECTION

DIAL GAUGE

DOUBLE DISC GRINDING

FACE GRINDING DONE HERE FOR BOTH FACES OF CONNECTING ROD

BIG END BORINGSMALL END BORING

.

SANSERA FINE BORING MACHINE

FINISHED FINE HONING FOR BIG END & SMALL END

VERTICAL HONING MACHINE

WASHING MACHINEREMOVAL OF OIL AND WATER FROM THE

COMPONENT SURFACE

BENDING TEST-8micronsTWISTING TEST-12micronsCENTRE TEST-250 to 350mmSMALL END BORE DIA. CHECKINGBIG END BORE DIA. CHECKINGVISUAL INSPECTIONDISPATCH

ALL THE PROBABLE CAUSES ARE LISTED BELOW

MACHINE MEASUREMENT

MATERIALMETHODMAN

FISH BONE DIAGRAM

MACHINE

FLOAT PAD MISMATCHARM SCREW OVERTIGHTCENTRE HEIGHT POINT PROBLEMIMPROPER INSERTLOCATOR PROBLEMINCORRECT FIXTURE

MEASUREMENT

WALL THICKNESS VARIATION DIAMETER VARIATION PITCH DISTANCE VARIATIONMATERIAL SPECIFICATIONS

MAN

UNSKILLED OPERATORLACK OF EXPERIENCELAZYNESSLACK OF CONCENTRATIONURGENCY

METHOD

UNCONVENTIONAL METHODINCORRECT TOOL SELECTIONIMPROPER PROGRAMMINGFLOT PAD MISMATCH

TRAIL SHEET

FIXTURE CALIBRATION REPORT

Through trials we have concluded that unclear occurs during boring and honing operations

actual CAUSES FOR UNCLeaR Float pad mismatch of the work piece Arm screw over tight Variation in Centre distance Power failure problem Smaller end arm tool problem Locator problem Incorrect component loading Incorrect fixture Butting , improper resting of work piece (The piece get crossed

or work piece move sideways) Offset setting changes

SUGGESTION TO REDUCE UNCLEAR

Arm screw should be properly tightened, otherwise component lifts

There should be frequent supply of power, otherwise taper, step lines and unclear occurs

Insert should be changed within 150 in number, otherwise undersize occurs

If insert is changed NT system should be controlled properly

After face grinding symmetry must be checked once again Operators should be well trained