Amtek persentation aman (11 me-06)

RING GEAR PRODUCTION

MPT AMTEK AUTOMOTIVE LTD.

Presentation By:Aman KumarRoll No: 11-ME-06MECHANICAL-A VIII SEM

ABOUT MPT AMTEK AUTO LTD

• Magna Powertrain and Amtek Establish a Joint Venture in India

• The Amtek Group was established in the year 1985 with the incorporation of the Flagship Company, Amtek Auto Limited

• Amtek is a leading multi-national manufacturer of automotive components and assemblies with production facilities located strategically across Asia, Europe and USA

• The current turnover of the group

exceeds $ 750 million.

ACHIEVEMENTSAmtek Auto recently won the best investor of the year award 2008 – UK Trade & Investment.

Adjudged ‘Best Performing Vendor 'Technology group Machine Parts Maruti Suzuki (1994–95)

• TVS Motors Ltd to Amtek Bhopal(2002–03)• Forging and Casting group from Honda Motor Cycles & Scooters India Ltd to

Amtek Bhopal (2005–06)• Honda Motor Cycles Scooters India Ltd (2005–06 & 2006–07) to Amtek Bhopal

Won ‘Supplier of the Year’ Award

• Prestigious ‘ET– Best Emerging Company of the Year 2006’ at ‘The Economic Times Awards For Corporate Excellence’

Declared ‘ET– Best Emerging Company of the Year’

MANUFACTURING PLANTS

Technology and Transcends Boundaries

Thriving on challenges Amtek registered its presence across North America, Europe & Asia to cater a number of client. And is poised to explore new global frontiers to invent new products and scale to new heights.

AMTEK WORLDWIDE CENTERS

INDIA

U.S.A

MEXIO

BRAZIL

ITALY

U. K

HUNGARY

GERMANY

AMTEK INDIA

RING GEAR/FLYWHEEL

ASSEMBLY

Gurgaon

Dharuhera

CASTING

Rajangaon

FORGING

DharuheraUnit II

Gurgaon

Bopal

Chakan

Ahmednagar

MACHINIG

Sohna

Gurgaon

Dharuhera Unit I

Dharuhera Unit II

Sanaswadi

Nalagrah

Maneser

Maneser

Chakan

Ahmednagar

FORGING is the process of forming hot / cold metal

CASTING is the process of forming from molten metal.

MACHINING is the term used for a set of metal – cutting processes which are performed on Forgings and / or Castings to give them the exact shape and size for assembling in the vehicle

ASSEMBLY is the processes making a product by the combination attachment of different elements

MANUFACTURED PARTS

Connecting Rod Assemblies

Flywheel Ring Gears and Assembly

Steering KnucklesSuspension and

Steering Arms CV jointsCrankshaft

Assemblies

PRODUCTION PROCESSRAW MATERIAL

(Trapizodial Bar Of Alloy Steel)

INWARD INSPECTION(To Verify The Dimensional And Metallurgical Parameter )

BLANKING

MACHINING

HOBBING

CHAMFERING

WASHING

INDUCTION HARDENING

FINISHED COMPONENT

FLOW CHART OF RING GEAR PRODUCTION LINE

RAW MATERIAL (QUALITY

CHECK)

BENDING MACHINE

SLITTING MACHINE

BUTT WELDING MACHINE

TRIMING MACHINE

NORMALIZINGMACHINE

COLD SIZING MACHINE

CNC MANCHINE

QUALITY GATE 1

HOBBINGMACHINE

CHAMFERING MACHINE

PUNCHINGMACHINE

WASHING MACHINE

INDUCTION HARDENING MACHINE

QUALITY GATE 2

BENDING Bending Machine is used to bend the square or trapezoidal

bar into ring form

The bending m/c has three rollers

A. Upper roller

B. Right roller

C. Left roller

The rod is kept on the left & right roller and then press by the upper roller then move in the clockwise direction.

BENDING BENIF ITS AND D IS ADANTAGESBuilding out from each end enables construction to be done with little disruption to navigation below

The span can be greater than that of a simple beam, because a beam can be added to the cantilever arms

Spring loose Irregular coiling Bending with T1

outside

OK SAMPLE PRODUCT DEFECTIVE PRODUCT

AFTER BENDING

SLITTING Slitting machine is used to cut the ring coil form in

bending machine in different rings By pressing the five coils ring and cut into different

parts.

Cycle time is 40 sec.

Cycle operation time is 120 min.

Hydraulic pressure - 35-55 kg/cm³ Slatted product

FLASH BUTT WELDING & TRIMMING Flash butt welding is a type of resistance welding without

using any filler metal

PARTS OF TRIMMING AND BUTT WELDING:-

o Flash butt welding and trimming machine

o Top clamp

o Electrode

o Trimming resting pad

o Trimming bit

o Horizontal cassete

o Vertical cassete

Trimming is the processes in which unwanted and extra material is removed by the special tool.

TRIMMING

APPLICATIONS Railway Lines (Flash butt welding machines are often

transported to the work site on a road-rail vehicle)

Chains

Steel wheels

Sheets or rods of steel in rolling mills.

Starter rings

NORMALIZING A necessary first step in the heat treatment process involves

"normalizing," a process designed to present a homogenous microstructure to the carburizing process

Normalizing is a process that involves heating a part above the upper critical temperature and then typically air cooling outside the furnace to relieve residual stresses in a gear blank and to aid dimensional stability.

PRODUCT AND MACHINE SPECIFICATION

Hardness - 85-95 HRBGrain size - 5-8 ASTMMicro structure - normalized structure Uniformly distributed ferrite

with pearlitePower level - 24%-28%Heating time - 20-25 secMin temperature - 800 ·cMax temperature - 890 ·c

COLD SIZING

Cold sizing is a squeezing operation performed at temperatures

significantly below the melting point to finish the surface of a work

piece to ensure better dimensional accuracy and surface finish.

PRODUCT AND MACHINE SPECIFICATION  

Specification for part NI-XH5

Internal diameter - 287.5±0.5 mm at three points

Ovality - 0.40 mm max

Flatness - 0.40 mm max

Trimming depth on both faces - ±0.50 mm

Hydraulic pressure - min 130 kg/cm²

Hold time - 35

CNC MACHINECNC means Computer Numerical Control. This means a computer converts the design produced by Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the coordinates of a graph and they control the movement of the cutter. In this way the computer controls the cutting and shaping of the material

 ADVANTAGESCNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same. CNC machines can be updated by improving the software used to drive the machinesLess skilled/trained people can operate CNCs unlike manual lathes / milling machines etc. which need skilled engineers

APPLICATION Industries for Fabricating Metals Electrical Discharge Machining (EDM)

Industry

CNC Turning

DISADVANTAGES

 CNC machines are more expensive than manually operated machines, although costs are slowly coming down.

The CNC machine operator only needs basic training and skills, enough to supervise several machines. In years gone by, engineers needed years of training to operate Centre lathes, milling machines and other manually operated machines. This means many of the old skills are been lost.

QUALITY GATE 1In the Ring Gear production are the following quality check is to be done:-

ID (internal diameter)

OD (outer diameter)

OVALITY

GEAR PROFILE MOT (Measurement of Teeth) DOP (diameter of pin)

ID AND OD GAUGE

HOBBING Hobbing is a machining process for gear cutting, cutting splines,

and cutting sprockets on a hobbing machine, which is a special type of milling machine.

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 inexpensive.

HOBBING CUTTER

THIS LIST OUTLINES TYPES OF HOBS:

1. Roller chain sprocket hobs

2. Worm wheel hobs

3 .spline hobs

4. Chamfer hobs

5. Spur and helical gear hobs

6. Straight side spline hobs

7. Involute spline hobs

8. Serration hobs

9. Semi topping gear hobs

PRODUCT AND MACHINE SPECIFICATION   Specification for part Mazda fz2 Measurement of teeth over 14 teeth -105.39±0.07 mm

MOT variation - 0.10 maxRoot diameter - 291.95±0.10

mmGear profile - deflection

should not be more than 0.35 mm on

dial indicatorNo. of teeth - 117 Hobb cutter specificationClamping pressure - 30-40 kg/cm²Axial feed - 1.4-1.9 mmHob run out - 0.05 maxFixture run out - 0.04 maxRPM of hob - 100-150Stack height - 11 nos

AFTER HOBBING PROCESSES  

CHAMFERRING A chamfer is a transitional edge between two vertices of an

object. It can also be known as a bevel but connotes more often

cutting and more often 45°

"Chamfer" is a term commonly used in mechanical and manufacturing engineering.

MACHINE PARTS Chamfering m/c

Chamfer cutter

Fixture

Top plate

Chamfering is not done all the model of the ring gear

Ring gear after the chamfering processes

PUNCHING AND WASHING

Punching:- Punching is a metal forming process that uses a punch

press to force a tool, called a punch, through the work piece to create a hole via shearing. The punch often passes through the work into a die. A scrap slug from the hole is deposited into the die in the process

This is use to punch the batch/lot number on face of ring gear.

Washing

Washing is basically an industrial bath. In this processes ring gear is washed out the industrial chemical which remove the unwanted material and provide a protection layer to ring gear from the corrosion

INDUCTION HARDENING Induction hardening uses induced heat and rapid cooling

(quenching) to increase the hardness and durability of steel.

Induction is a no-contact process that quickly produces intense, localized and controllable heat.

GEAR AT INDUCTION HARDENING

INDUCTION HARDENING  1. Power S1% - 60-65%2. S1 time sec - 5-73. Power S2% - 60- 704. S2 time sec - 4-65. Heating dwell time - 006. Quenching temperature - 50±3°c7. Quenching flow in LPM - 200-2508. Quenching time sec - 25±39. Hardening position - 176±1010. Concentration of polymer - 21-2311. Polymer checking - cooling

crick12. Fixture forces - 0.2 max

TEMPERING Induction tempering is a heating process that optimizes

mechanical properties such as toughness and ductility in workpieces that have already been hardened.

The main advantage of induction over furnace tempering is speed

Gear at Induction Tempering

INDUCTION TEMPERING  

1. Power % - 5-82. Heating time - 5±23. Dwell time - 0.5±0.25

QUALITY GATE 2Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. ISO 9000 defines quality control as "A part of quality management focused on fulfilling quality requirements"

This approach places an emphasis on three aspects 

1. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, and qualifications

3. Soft elements, such as personnel, integrity, confidence, organizational culture, motivation, team spirit, and quality relationships.Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example