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8/3/2019 lalit kashyap

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What is gear!

GEAR IS ATOOTHED WHEELWHICH IS USEDTO TRANSFORM

POWER.


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The processes driven in gear

manufacturing FORGING TURNING / FACE GRINDING BLANK INSPECTION HOBBING / SHAPING SHAVING HEAT TREATMENT SHOT BLASTING CENTRE CLEANING STRAIGHTING MARKING

OUTER DIAMETER GRINDING INNER DIAMETER GRINDING WASHING OILING ASSEMBLY INSPECTION PACKING


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Hard Machining ProcessHOBBING:-

It is the very first machining process. In it we did teethcutting on the job. The jobs material is 16 Cr Ni O4.

The cutting material in hobbing machine is M-5.

Hobbing is done on LIEBHERR machine which ismade in Germany and its model is LC-150.

The teeth cutting is done by the help of a coolantwhose name is iolo cut 945.which is made by Castroloil company.


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SHAVING:-It is the second process after teeth cutting afterhobbing there are some burr on the hobbedmaterial/job. To remove them we use shaving process.It is also used as finisher of the hobbed material.

Shaving is done on Mitsubishi machine which is madein Japan and its model is FE30A.

The finishing of the material is done by the help ofshell grain 405 M 22 cutting oil.


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SHAPING:-It is also a machining process. In it we also done teethcutting but in this process the teeth cutting is done onshafts where the distance between teeths are very low.

Shaping is done on LIEBHERR machine which ismade in Germany and its model is LS-150.

The shaping process is done by the help of a coolantwhose name is CASTROL GLYCOL REFRIGERMANT(CGR).


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24 gp


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16 fp


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Heat Treatment ProcessThere are five basic steps & three secondary steps-BASIC STEPS-

Pre washing

Pre heating Sealed quenching Post washing Tempering

SECONDRY STEPS- Center cleaning Straighting Marking


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PREWASHING:-In pre washing the job is warmed to 150C for 30minutes by the help of water with the help of loadtable it is send to the pre heating furnace

machine.

PREHEATING:-In pre heating the material/ job is warmed to 750Cfor 60 minutes by which the material is ready forthe next process which is carburizing.


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SEALEDQUENCHING:-In this process the carburizing is done on 920C. Inpre heating the percentage of carbon is 0.65% butafter carburizing is becomes 0.95%.

By the increasing in temp to 920C, the job becomerough and there is some fractures on it todecrease the roughness as fractures we done thepre heating process.

The pre heating & quenching is done by the helpof LPG gas the next process is post washing.


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POST WASHING:-After carburizing the temperature of the job is950C to cool the job we done post washing in it wetake the jobs temperature to 120C by the help of

water and ammonia.TEMPERING:-

Tempering is done for the removing of crackswhich are becoming in the process carburizing.


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Three Secondary Steps Centre cleaning: - In it the jobs are washed by the help of water so the

remaining carbon gets removed.

Straighting: - If there are some bent after the carburizing, to remove thebent of job, we done straighting. It is done by the help of pressure.The straighting machine is work on the mechanical pressure.

Marking: - To know the properties of the jobs and to get the batchnumber, we done the marking on the job. For example:-

D10E148

Where D means APRAIL (Month)Where 10 means 2010 (Year)Where E148 means batch no. & fixture no.

This is done by the help of MARKMAN which is made in switerzerlandand its model is MK-300.


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SHOT BLASTING:- It is a part of heat treatment process. In it we done

deburring of the job. In it we through the bullets of steel of0.8mm diameter at a very high speed. By the high speed thesteel bullets are driven on the job so the deburring of thejob get completed.

This process is done by shot blasting machine which is fullycovered by steel gates. This machine is made by Disa Engg.& its model is VP-14.238. This machine is made in INDIA.

After the shot blasting the job is sent for the grindingbecause grinding process is done on hard material/job.


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SOFT MACHINING

I/D GRINDING:- In I/D grinding we finishing the inner diameterof the job. This process is done on PMT MACHINE. In the plantthere are two types of PMT MACHINES

FIG 100FIGE 150The I/D grinding is done by the help of coolant ( water + cutting

oil ). O/D GRINDING:- In O/D grinding we finishing the outer

diameter of the job. This process is done on JUNKER machine.

The O/D grinding is done by the help of coolant ( Castrol HyspinAWS 46 Hydraulic OIL ). By the help of JUNKER machine we cangrinding of 10 diameters on a single piece and in a single time.The only drawback of JUNKER is that it takes about 2 minutes ina cycle. So its production rate is little low.


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Job after soft machining


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Last Process WASHING- It is done by the help of WATER and AIR

PRESSURE. This process is driven separately for shafts andgears.

ASSEMBLY-Assembly is the last mechanical process of thegear plant. In it we assembles the gear by the help ofSYSPAC GEAR ASSEMBLY M/C. This machine is made by anAustrian company named SYSPAC. These are two machinesin the quantity.

After the assembling the piece is sentto PDI room for last inspection. After PDI room it sent toPACKING CHAMBER to given to the costumers.


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GEAR ASSEMBLY

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