Name – Anurag mishra

)

Govt. Polytechnic - Manesar

Summer Training Report ( On Ring Gear Manufacturing Process )

AcknowledgementEvery 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.

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Contents

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About the Company List of Customers

About The Product

Manufacturing PFD

Process Introduction

IN-House Testing And Checking Facilities

ABOUT THE AMTEK GROUP

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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.

AMTEK GROUP OVERVIEW - SNAPSHOT

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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 CustomersBorgWarner, 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

AMTEK CUSTOMERS

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2/3 Wheelers Passenger Cars

Light Commercial

Vehicle

Heavy Commercial

VehicleOthers

Auto Sector

Tractors Railways Others

Non - Auto Sector

AMTEK – ARGL ( RING GEAR DIVISION )

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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.

ARGL – MANUFACTURING PROCESS RING GEAR

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RAW MATERIAL BENDING SLITTING WELDING

HOBBING ID TURNING OD TURNING COLD SIZING

FINAL GEARWASHING HARDENING TEMPERING DE-BURRING & PUNCHING

NORMALIZING

CHAMFERING

ARGL – MANUFACTURING PROCESS ( MACHINING)

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Ring Blank Shot Blasting Cold Sizing OD Turning

Ind. Hardening Tempering De - burring Ring Gear

Washing Chamfering Hobbing ID Turning

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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)

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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

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SLITTING PROCESS

Make regular spring coil to single part with help of cutter .

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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 .

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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 :-

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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.

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TURNING PROCESS

At this process remove the extra material and maintained the required specification. This process

done with help of CNC Turning Machine.

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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.

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GEAR CUTTING PROCESS

Hob Cutter

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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.

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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.

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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.

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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.

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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.

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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.

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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,

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

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Testing InfrastructureStandard Room

Metallurgy Lab Testing Instruments Calibration

Hardness TesterVickers Rockwell

Hardness TesterMicroscope Dial Calibration

MasterMicrometer

Callibration MasterHeight Master

IN-HOUSE TESTING AND CHECKING FACILITIES

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THANK YOU