Transcript SUMMER TRAINING AT

INDUSTRIAL TRAINING
AT
Mahindra Gears & Transmissions Pvt. Ltd.
Shapar Road, Rajkot (Gujarat)
Prepared By: Faldu Krunal
B. Tech 4th Year (7th Semester)
Mechanical Engineering
J.N.U. JODHPUR
R.No: 08ET405079
•
INTRODUCTION

Mahindra gears is one of the
leading
manufacturing
of
proven quality gears and other
transmission component in
India since 1987. The facility
comprises of 3 work shops of
sizes 800 sq. mts, 1000 sq. mts,
4000 sq. mts. With a complete
stand by power for the entire
premises.
SERVICES & MAJOR FUNTION
 Mahindra Gears & Transmissions Pvt. Ltd. Produce more than
2,50,000 quality assured gears a month, conforming to German
specification DIN 7 to DIN 9 class of accuracy. They are certified
to TS 16949 quality system requirements, from TUV.
 Mahindra Gears manufactures auto components comprising of
automobile gears like Spur, Helical, Straight Bevel, Sprockets along
with Transmission Saline Shaft, Couplings and Power Takeoff
Clutches which are used for Transmission, Engine and Differential
gear boxes.
VARIOUS DEPARTMENT /SHOP






New Production Development Department
Vendor Supplied Area / Raw material Storage
SCM department
Primary Inspection Department
Maintenance Department
Production Shop
 Heat Treatment shop
 Shot Blasting Shop
 Grinding Shop
 Eaton Hub Cell
 Pre Dispatch Inspection Department
 Final Inspection (Domestic/Export)
CUSTOMER
 International Tractor Ltd.
 Tata Motors Ltd.
 DANA India Ltd.
 Eaton Hub Pvt. Ltd.
VENDORS
 Forging
1.
2.
3.
Kadvani Forge Ltd.
Niku Forging Pvt. Ltd.
Hindustan Motors Pvt. Ltd.
 Machining
1.
2.
3.
Jyoti CNC Automation
Turn well Industries
Krishna Engineers
 Heat Treatment
1. Ravi Metal Treatment
2. Inducto Hardening
3. Advance Mechanical Works
MANUFACTURING PROCESS
 HOBBING:-
PROCESS
 Hobbing is a machining process for making gears & splines. 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 in expensive.
SHAPPING:-
PROCESS
 A gear shaper is a machine tool for cutting the teeth of internal or
external gears. The name shaper relates to the fact that the cutter
engages the part on the forward stroke and pulls away from the part
on the return stroke, just like the clapper box on a planer shaper.
The cutting tool is also gear shaped having the same pitch as the
gear to be cut.
BROACHING:-
PROCESS
 Broaching is a machining process that uses a toothed tool called a
broach to remove material. This are two mainly type of broaching
(Horizontal & Vertical). It is the most common used process to cut
internal gear quick and more accurate. Broaching is used when
precision machining is required, especially for odd shapes.
Commonly machined surfaces include circular & noncircular holes,
splines, key-ways and flat surface.
SHAVING:-
PROCESS
Gear shaving is basically a finishing operation. This takes
place after the operations of roughing with a hob or
cutting with a shaper cutter is over. The Shaving process
consists of the removal of tiny particles of metal from a
gear teeth's working surface. Gear shaving produces fine
hair like chips. The cutter comes in the form of helical
gear. It has special serrations in the flank area of gear
teeth. These “serrations” act as the cutting edges.
ADVANTAGES
1. Improves tooth surface finish.
2. Effective reduction in the noise of gears with
modification in the tooth profile.
3. Increase the gear’s load capacity Improved safety and
service life.
SHOT BLASTING:-
 Shot Blasting is the
process
after
Heat
treatment in which
remove the product
darkness which occurs
in
heat
treatment
process . In this Process
52 to 60 HRC stainless
steel particles strike on
product.
DEBBURING:-
 Gear deburring machines are
designed to correctly remove burrs
or sharp edges as a result of
castings, drilled holes, cut grooves
and other machining operations
used to complete parts. The
Deburring process of gears makes
the parts capable of a performance
for which they were designed. It
eliminates all the unwanted
elements that obstruct their
productivity.
ROUNDING: Rounding is a process in
which
the
tooth
sharp
corner is cut by the rounding
cutter. A rounding cutter is an
exterior corner is called a
"round" or a "radius”.
LAPPING: Lapping is a machining operation, in which two surfaces are
rubbed together with an abrasive. The one type of lapping (called
grinding), typically involves rubbing a brittle material such as
aluminum oxide, emery, silicon carbide, diamond, etc., in between
them. This produces microscopic conchoidal fractures as the
abrasive rolls about between the two surfaces and removes
material from both.
GRINDING MACHINE:-
PROCESS
 Grinding machine consists of a power driven grinding wheel
spinning at the required speed. The grinding head can be
controlled to travel across a fixed work piece or the work piece
can be moved while the grinding head stays in a fixed position.
Very fine control of the grinding head or table’s position is
possible using a vernier calibrated hand wheel, or using the
features of numerical controls.
Turning machine: Turning is the process where
by a single point cutting tool is
parallel to the surface. It can be
done manually, in a traditional
form of lathe, which frequently
requires continuous supervision
by the operator, or by using a
computer
controlled
and
automated lathe.
Hard turning
 Hard turning is a turning done on materials with a Rockwell C
hardness is greater than 45. It is typically performed after the work
piece is heat treated.
 Soft turning
 Soft Turning is turning done to soft materials which are without
heat treatment process and its hardness is lower than Rockwell C
hardness 45.
HEAT TREATMENT PROCESS:-
PROCESS
 Heat treatment process is a series of operations involving the
heating and cooling of metals in the solid state. Its purpose is to
change a mechanical property or combination of mechanical
properties so that the metal will be more useful, serviceable, and
safe for definite purpose. By heat treating, a metal can be made
harder, stronger, and more resistant. No one heat-treating
operation can produce all of these characteristics. In fact, some
properties are often improved at the expense of others. In being
hardened, for example, a metal may become brittle.
PROCESS FLOW CHART