mats ppt (draft)

8/4/2019 Mats Ppt (Draft)

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MATS Training


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Brief Information about the

companyMOTHERSON ADVANCED TOOLING SOLUTIONS LIMITED (MATS) is a significantpart in the metal division of the world-renowned group SAMVARDHANAMOTHERSON.

Motherson Advanced Tooling Solutions Limited (MATS) was incorporated byacquiring Broaches & GCT business from Dagger-Forst Tools Limited wef 01ST

June 2009. MATS are pioneers in manufacture of high quality broaches and HSSGear Cutting Tools in India. We have 4 manufacturing sites located in WesternIndia fully equipped with state of the art manufacturing and testing facilitiesincluding in-house Heat Treatment facilities. All plants are ISO 9001: 2000certified.

We are market leaders in India & also have a considerable market share in USA,Europe, RSA, Iran, South East Asia, Australia etc. Reputed automobilemanufacturers like GM, Ford, Hyundai, Eicher, Hero Honda, Suzuki and Yamaha areour valued customers along with auto component manufacturers like Dana Spicer,Fair Field, GKN and Graziano Transmissions.


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Products made in MATS

1. Hobs

2. Broach (internal)

3. Broach (flat)

4. Gear Shaver


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What is broaching ? Broaching is a machining process that uses a toothed tool, called a

broach, to remove material. There are two main types of broaching: linearand rotary. In linear

broaching, which is the more common process, the broach is run linearlyagainst a surface of the workpiece to effect the cut. Linear broaches areused in a broaching machine, which is also sometimes shortened tobroach.

In rotary broaching, the broach is rotated and pressed into the workpieceto cut an axis symmetric shape. A rotary broach is used in a lathe or screwmachine. In both processes the cut is performed in one pass of thebroach, which makes it very efficient.

Broaching is used when precision machining is required, especially for oddshapes. Commonly machined surfaces include circular and non-circular

holes, splines, keyways, and flat surfaces. Typical workpieces include smallto medium sized castings, forgings, screw machine parts, and stampings.

Even though broaches can be expensive, broaching is usually favored overother processes when used for high-quantity production runs.[1]


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ROUND BROACH

Application:

Internal :- Round, Keyway, Straight or InvoluteForm, Serration & Special Internal profile.Design Capabilities:Any Special Profilerequirements.

Material:M2, M35, M3 Type II, M42, ASP23,ASP30, CPM T15, CPM M4

Size Range:Round & Spline Dia. 15mm250mm, Length upto 2000mm Flat width 4mmto 200mm

Accuracy:Within 0.01mm


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Process followed

Raw material cutting

Pilot and taper turning

Teeth cutting Soft Machining

Spline milling

Heat treatment

Centre grinding

Rough cylindrical grinding Grinding process

Sharpening (rough) ( Profile generation)


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Gullet

Finish cylindrical grinding

Sharpening (finish)

Profile grinding

Round and flat holding Grinding process Nicking

Inspection and trial

Marking and packing


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Flat broach

Application:

External :- Connecting Rods, Turbine Blades,

Shifter Forks, Steering Racks. Design

Capabilities:Any Special Profile requirements.

Material:M2, M35, M3 Type II, M42, ASP23,

ASP30, CPM T15, CPM M4, Size Range:Round &

Spline Dia. 15mm 250mm, Length upto2000mm Flat width 4mm to 200mm

Accuracy:Within 0.01mm


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Process Followed


Width and thickness milling

Taper milling

Teeth milling Soft

machining

Extra material removing

Milling pull end / rear endHeat treatment


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Grinding bottom width

Grinding top , teeth size and taper

Grinding of angle block and keyway

Grinding profile Profile

Holding making

Nicking

Back off

Inspection

Packing


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What is hobbing ?

Hobbing is a machining process for making gears,splines, and sprockets on a hobbing machine, which isa special type of milling machine. The teeth or splinesare progressively cut into the workpiece by a series of

cuts made by a cutting tool called a hob. Compared toother gear forming processes it is relatively inexpensivebut still quite accurate, thus it is used for a broad rangeof parts and quantities.

It is the most widely used gear cutting process for

creating spur and helical gears and more gears are cutby hobbing than any other process since it is relativelyquick and inexpensive.


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Hob

Module: 0.5 M 20 M; Dia. : 50 to 250 mm

(also DP series)

Start: Single or Multi Start.

Accuracy: AA, A, B & C (as per DIN 3968)

Forms : Non-Topping, ST, T, finishing, pre-

shaving, pre- grinding, with or without

protuberance, tip relief, full fillet, etc.Material : M35, M42, ASP 30, ASP 2052, etc.

Each Item tested on Hoffler Gear Tester.


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Process followed


Facing

Drilling

Boring , Recessing

Rough turning

Finish turning Soft machining

Keyway cutting

Thread cutting

Gash milling

Releving


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Heat treatment

Face grinding

Proof diameter grinding

Bore grinding profile making

Sharpening of cutting edge

Profile grinding

Nicking

Marking

Inspection


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What is shaving

Gear shaving is basically a finishing operation.This takes place after the operations ofroughing with a hob or cutting with a shaper

cutter is over. The Shaving process consists ofthe removal of tiny particles of metal from agear teeth's working surface. Gear shavingproduces fine hairlike chips. The cutter comes

in the form of helical gear. It has specialserrations in the flank area of a gear teeth.These serrations act as the cutting edges.


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Shaving cutter

Improved surface finish of flanks and accuracies ofprofileProduce high accurate gear at low cost.Range : 170 mm to 260 mm PCD.Material : M2 & M3 (II) type of HSS material.Also carry out resharpening with profile correctionModule : 0.8 M to 6.35 M.Special design for lower than 1.50 modules.Used for finishing operation of Gears for Automobile

Transmission & other similar Engg. Industry.Each Item tested on Hoffler Gear Tester.


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Process followed

Raw material stress relieving

Drilling

Boring

Chamfering

Grooving soft machining

Facing

Turning

Rotary grinding

Soft bore grinding


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O D grinding

Hobbing

Root milling soft machiningSerration

Keyway cutting

Heat treatmentRotary grinding

Grinding bore (finish)

Profile grinding profile makingOD grinding

Inspection

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