INDUSTRIAL TRAINING REPORT MPT AMTEK AUTOMOTIVE LTD. (RING GEAR PRODUCTION) 9 th Feb 2015 - 9 th Aug 2015 Department of Mechanical Engineering B.M. COLLEGE OF TECHNOLOGY & MANAGEMENT M.D. UNIVERSITY, ROHTAK (HR) Submitted by AMAN KUMAR Roll No. 11-ME-06 Under the Guidance of Mr. MANISH KUMAR Mr. MAHENDER SINGH (Faculty Coordinator) (Production Head) H.O.D, Mechanical Engg. MPT AMTEK AUTOMOTIVE LTD. BMCTM, M.D. University Dharuhera, Rewari
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INDUSTRIAL TRAINING REPORT
MPT AMTEK AUTOMOTIVE LTD.
(RING GEAR PRODUCTION)
9th Feb 2015 - 9th Aug 2015
Department of Mechanical Engineering B.M. COLLEGE OF TECHNOLOGY & MANAGEMENT
Castings, Amtek has facilities for Aluminum Castings at Bourne (U.K) and is in the process of
commissioning another Aluminum Casting facility at Ranjangaon (Mah.).
Machining:-
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. The Group
has Machining facilities within India at Gurgaon (Haryana), Sanaswadi (Mah), Manesar &
Dharuhera (both in Haryana), Baddi (H.P), and across the World at Letch worth, Coventry &
Bourne (in U.K) & Hennef (Germany), Stanberry, Bay City & Kellogg (in USA).
Assembly: -
The Assembling activities are carried at Letch worth, Coventry, Gurgaon, Dharuhera, & Hennef
(Germany). The products include Bridge Fork Assemblies, Strut Assemblies, Wheel Corner
Modules, Axle Assemblies, Turbochargers, Piston Cylinder Modules, Spindle Assemblies, and
Fuel Delivery Systems.
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ACHIEVEMENTS
VISION
We aspire to be the most preferred and reliable provider of products & services globally, with an
unflinching commitment towards technological excellence
CORE VALUE • Customer Focus
• Commitment to Excellence
• Openness, Fairness and Trust
• Team Spirit
Amtek 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’
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1.3 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
FIG No. 1.3 Amtek Map
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EUROPE
Letchworth (UK) GWK Amtek Machining
Coventry GWK Amtek Machining
Hennef (Germany) - I
- II
Zelter Machining
Zelter Machining
Witham (UK) Amtek Investments
UK Limited
HPDC Aluminium Casting
USA
Bay City (MI) Amtek Gears (Amtek
Inv US)
Ring gears / Flywheel assembly
Kellogg (IN) Midwest Mfg.
(Smith Jones)
Ring gears / Flywheel assembly
Stanberry (MO) Midwest Mfg.
(Smith Jones)
Ring gears / Flywheel
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AMTEK INDIA
RING GEAR/FLYWHEEL
ASSEMBLY
Gurgaon
Dharuhera
CASTING
Rajangaon
FORGING
Dharuhera
Unit I I
Gurgaon
Bopal
Chakan
Ahmednagar
MACHINIG
Sohna
Gurgaon
Dharuhera
Unit I
Dharuhera
Unit I I
Sanaswadi
Nalagrah
Maneser
Maneser
Chakan
Ahmednagar
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FIG No.1.4 Amtek across India
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1.4 CUSTOMER PROFILE
AUTO SECTOR CUSTOMERS
2/3 WHEELERS
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PASSENGER CARS
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LIGHT COMMERCIAL VEHICAL
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HEAVY COMMERCIAL VEHICAL
OIHER
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NON AUTO CUSTOMER
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1.6 MANUFACTURED PARTS
Product range of the company includes:
Amtek product portfolio consists of an extensive range of components for 2–3 wheelers, Car,
Tractors, LCV, HCV and Stationary engines. The major categories of components manufactured
are,
Connecting Rod Assemblies
Flywheel Ring Gears and Assembly
Steering Knuckles
Suspension and Steering Arms
CV joints
Crankshaft Assemblies
Torque Links.
FIG No.1.5 Manufacture Parts
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MODEL OF RING GEAR
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The main objective of the Training is to study the Production process of the Amtek MAGNA
Powertrain Ltd. And to analyses the Production process and defects of the Amtek MAGNA
Powertrain Ltd... The study includes the study of all control plans of the products and machining
processes etc. The main objective in working with the production process is to calculate the
production rates with in time and without any defects.
My duty in company was to understanding and studies the production of Ring gears process. MPT
AMTEK deals with the production or machining of ring gear. It is a joint venture of Amtek group
OBJECTIVES OF THE STUDY & LITERATURE REVIEW 2
UNIT
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DEFINITION:-
A starter ring gear, sometimes called a starter ring or ring gear, is a medium carbon steel ring
with teeth that is fitted on the periphery of a flex plate or flywheel of an internal combustion engine,
mostly for automotive or aircraft applications. The teeth of the starter ring are driven by the smaller
gear (the pinion) of the starter motor.
The primary function of the starter ring is to transfer torque from the starter motor pinion to the
flywheel or flex plate to rotate the engine to begin the cycle.
Manufacture
The starter ring gear is most commonly made by forming a length of square or rectangular steel
bar into a circle and welding the ends together. There then follow various operations such as
normalising (to remove stresses and improve the properties in the weld area), turning, generating
the teeth by gear hobbing and finally a heat-treatment operation(s). The teeth of the starter ring
need to be hardened in order to increase their strength and resist wear. The normal hardness at
pitch circle diameter is 45-55 HRC. The body of the ring is generally left untreated which gives
some ductility for shrinking onto a flywheel or welding to a flex plate.
Attachment
Engines with manual transmission usually have a heavy flywheel, typically 5 to 10 kg of cast iron,
with the starter ring gear shrunk onto the outside. This is done by heating the ring to around 200
°C to expand the ring which is then placed onto the flywheel, often held in firmly against a location
shoulder until cool. The interference fit renders the starter ring firmly attached to the flywheel. [1]
Engines with automatic transmissions instead have a pressed steel plate with the starter ring gear
usually welded onto the outside of the plate
RING GEAR 3
UNIT
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FIG No. 3.1 Ring Gear
Fig No. 3.2 Ring Gear Use
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FIG No. 3.3 Raw Material
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PRODUCTION PROCESS
Ring Gear Manufacturing
1. Blanking: Blanking process the rolling of a straight trapezoidal bar of steel into a coiled form; slitting the entire coil at a point to separate each steel loop of the coil which in the
form of ring but silt at point; flash butt welding together of the separate end of the loop together to form a complete ring; removal of extra welding flash from the ring; tempering
of the welded ring to revealed the stress created in the ring during welding and finally this operation is followed by the shot blasting operation, which is done to remove the scales form during the normalizing operation. After this operation being completed the ring are
press on the hydraulic press to rectify any deformation created during the previous processes. Now the ring is ready for machining.
2. Machining: the machining processes involved is turning. Basically the turning operation on a ring is done in two step. In the first step & the internal diameter is turned to specific
size and surface finish. The cycle time to this operation is varies between 1-1.5 minutes depending on the size of the ring. In the second step outer diameter & outer face is turned
and the cycle time varies between 1 - 1.5
3. Hobbing: The term hobbing is refer to the process of cutting the outer diameter of the machining ring into the shape of gear teeth by a specially designed cutting tool is called
the hob cutter. The profile and the shape of the cutter on the hob. Gera hobbing is performed on special purpose machine called the gear hobber and the fixture on which rings are held during the hobbing process is called the colleted type hobbing fixture which has a highly
intricate design which allow the fixture to contract and expand for the purpose of ring loading and unloading and after hobbing respectively. The cycle time of the operation
varies between 30-45 min.
4. Chamfering: In the chamfering process the sharp edges of the gear teeth on the clutch
side of the gear are removed to facilitate easy engagement of gear teeth with the pinion gear of the electric starter motor of the engine as to avoid any kind of friction, which may
occur otherwise during actual use. The approx. cycle time of the operation is between 50sec -120sec depending on the component.
5. Debarring & washing punching: In the process the loose chips of the metal which may
have stuck of the ring are removed and the gear are washed using antirust oil. This operation take around one minute. Punching of the batch code and the supplier code is alose done after this process.
6. Induction hardening: This is the operation of raising the surface hardness of the gear teeth
up to a specific level and the depth of the hardness is also controlled to achieve a specific case as per the design requirement of the costumer. Immediately after the induction Harding the gear are lowered in the quenching tank which contains any three liquid that is,
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oil, polymer or water. The cycle time for the operation varies between 20-40sec depending on the size the component and hardness required.
Ring Gear Manufacturing Process
RAW MATERIAL
(Trapizodial Bar Of Alloy Steel)
INWARD INSPECTION
(To Verify The Dimensional And Metallurgical Parameter )
BLANKING
MACHINING
HOBBING
CHAMFERING
WASHING
INDUCTION HARDENING
FINISHED COMPONENT
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There are several processes on the different machines is involves to produces the ring gear on the
production line. Product and machines have different specification at several processes.
FLOW CHART OF RING GEAR PRODUCTION LINE
RING GEAR PRODUCTION LINE 4
UNIT
RAW MATERIAL (QUALITY
CHECK)
BENDING MACHINE
SLITTING MACHINE
BUTT WELDING MACHINE
TRIMING MACHINE
NORMALIZING
MACHINE
COLD SIZING MACHINE
CNC
MANCHINEQUALITY GATE 1
HOBBING
MACHINE
CHAMFERING MACHINE
PUNCHING
MACHINE
WASHING MACHINE
INDUCTION HARDENING
MACHINE
QUALITY GATE 2
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1. 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. Then the process operate automatically form the ring shape. There is only
upper roller movement in vertical direction. The specification is given by customer.
The cycle time for bending machine is 15 sec.
The cycle operation is 120 min. Part name NI-XH5 specification Measuring INS
Inner diameter - 237.5-238.5mm VC
Upper roller position - 75±2mm
Vertical Hang Pin Position - 85±2mm
Fig No. 4.1 Bending Machine
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Fig No. 4.2 Bending Processes
After the bending processes raw material will be produced as shown in fig
Fig No. 4.3 after Bending
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OK SAMPLE PRODUCT
Fig No. 4.4
DEFECTIVE PRODUCT
Fig No. 4.5
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Bending Defects:- a. Spring loose
b. Irregular coiling
c. Bending with T1 outside
Fig 4.6 [Defects in bending]
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2. 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.
Slitting Machine Specification for NI-XH5 Ring gear measuring INS
After cutting diameter - 239-240 mm VC
Overlap - 2 mm minimum VC
Tool change frequency - 200 coils Production
Hydraulic pressure - 35-55 kg/cm³ Pressure gauge
Coolant - cool edge 3-5% Refract meter
Fig No.4.7 Slitting Processes
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PRODUCT ON SALTTING
Fig No. 4.8 Slatted product
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Fig No. 4.9 Slitting Machine
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3. FLASH BUTT WELDING & TRIMMING:-
Flash butt welding is a type of resistance welding without using any filler metal. It is used for
joining two metal parts together using heat and force. Each of the two parts to be joined is clamped
against an electrode, usually a copper alloy. The electrodes themselves being connected to the
secondary side of a transformer. The ends are brought slowly together until they just touch. At this
point a high current flows through the touching points, rapidly heating and melting the metal at
the points of contact. The molten metal is then expelled by its own rapid expansion. This part of
the welding cycle is called the flashing and generally creates a spectacular shower of sparks.
Voltage used is generally low (typically between 4 and 20 volts) but the current usually very high,
often in the tens of thousands of amps. The heat generated raises the temperature of either side of
the joint. Once the temperature is above the forging temperature (typically around 1,250°C for
steel) the ends are rapidly pushed together with great force. The high speed expels any remaining
molten metal and the high force generates enough pressure at the joint (around 90 megapascals for
steel) to 'forge weld' the ends together.
THE DIFFERENT CYCLES USED
Pre-Heating
Sometimes an optional pre-heating operation is used to heat the joint area using Joules energy from
passing a current through the joint area directly without any flashing. This heats the whole area
between the electrodes. Pre-heating itself is sometime preceded by a 'Burn off' cycle which
prepares the ends for better contact in the pre-heating cycle.
Flashing Operation
An important parameter is to attain the proper forging temperature around the joint. This is
generally dependent on the amount of heat generated by the flashing cycle. Flashing is typically
determined by either a pre-set amount of time (seconds) or a pre-set distance to be flashed away
(mm). Whereas pre-heating will heat the whole joint area that is between the electrodes, flashing
will instead generate heat only at the joint interface. Heat will then be conducted back into the joint
parent metal.
Butting a.k.a. upsetting
Once the correct temperature profile has been generated then the ends of the joint are rapidly forced
together. Initially a high velocity 'squirts' out any impure molten metal at the joint interface before
it solidifies. Further movement as the joint cools swells the joint area through an upsetting action
until the pressure at the joint, along with the temperature is sufficient to 'forge-weld' the ends
together.
Hold Time
At the end of upsetting there is commonly a 'hold time' during which the joint is held still to allow
the joint to cool and the two pieces of metal to completely bond.
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Applications I. Railway Lines (Flash butt welding machines are often transported to the work site on
a road-rail vehicle) II. Chains
III. Steel wheels IV. Sheets or rods of steel in rolling mills. V. Starter rings
Fig No. 4.10 Butt Welding Processes
PARTS OF TRIMMING AND BUTT WELDING:-
I. Flash butt welding and trimming machine
II. Top clamp
III. Electrode
IV. Trimming resting pad
V. Trimming bit
VI. Horizontal cassete
VII. Vertical cassete
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Fig No. 4.11 Flash Butt Welding Machine
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PRODUCT AND MACHINE SPECIFICATION
Specification for NI-XH5 Part
Internal Diameter - 237-238 mm
Welding strength - 542 Nmm² minimum
Ovality - 2 mm max without weld area
Trimming depth on both faces - 0.3 mm max
Trimming depth on ID - 0.3 mm max
Trimming depth on OD - 0.3 mm max
Electrode change after - 1500 pcs
Welding start position - 40±5 mm
Fleshing length - 4±1 mm
Butting length - 4±1 mm
Preheat - off
Free heat pressure - 0
Free heat count - 0.0
Initial fleshing velocity - 3.7±0.20 mm/sec
Initial current feedback - 2.0±0.20 amp
Acceleration - 4.0±1 mm/ sec²
Butting hold time - 1.2±20 sec
Fleshing time - 2±0.50 sec
Clamping pressure - 40±5 kg/cm²
Butting pressure - 30±5 kg/cm²
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4. TRIMMING:-
Trimming is the processes in which unwanted and extra material is removed by the special tool.
After the butt welding extra material is worn out on the welding spot, this is removed by the
trimming and trimming is done by the grinder, trimming machine.
Fig No.4.12 Trimming Machine
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Fig No.4.13 after Trimming
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5. NORMALIZING:-
Importance of Normalizing
A necessary first step in the heat treatment process involves "normalizing," a process
designed to present a homogenous microstructure to the carburizing process. To reduce
overall part distortion, it is highly undesirable to have this homogenization take place during
the carburizing cycle of a finished gear component. A separate normalizing cycle removes
the problems associated with pearlite and ferrite segregation. Ferritic areas do not transform
to the same hardness and stress levels as pearlitic areas when homogenized during the
carburizing cycle, resulting in more--not less--distortion.
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. Normalizing is often considered from both a thermal and
microstructural standpoint. In the thermal sense, normalizing is austenitizing followed by
cooling in still or slightly agitated air or nitrogen. In a microstructural sense, the areas of the
microstructure that contain about 0.8 % carbon are pearlitic, while the areas of low carbon
are ferrite. A normalized part is very machinable but harder than an annealed part. It also
relieves any residual stresses present from the steel making and forging processes that could
cause later distortion during carburizing.
A good normalizing cycle consists of holding the rough material "at temperature" for two
hours minimum, or one hour per inch of section thickness. The temperature should be the
same or higher than the carburizing temperature later used
PRODUCT AND MACHINE SPECIFICATION
Hardness - 85-95 HRB Grain size - 5-8 ASTM
Micro structure - normalized structure Uniformly distributed ferrite with pearlite
Power level - 24%-28% Heating time - 20-25 sec Min temperature - 800 ·c
Max temperature - 890 ·c
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Fig No. 4.14 (Normalizing Induction Machine)
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Fig No. 4.15 (Normalizing Induction Coil)
Product at the Normalizing Processes
Fig No. 4.16 Normalizing Ring Gear
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6. 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.
The sizing operation is a squeezing operation that minimizes the thickness of the metal. Sizing
is performed in an open die and only the surface where the die and work piece touch will be
sized. Many ferrous metal castings are sized to sharpen corners and flatten holes around
piercings. Sizing pressure is determined by area to be sized, the metal used, and the change in
metal thickness from the operation. Sizing is usually performed on semi-finished parts or parts
that require an accurate finish. Stop blocks are used to ensure close tolerances.
Cold sizing, like all other cold forming processes, has a hot process counterpart. In addition to
semi-finished parts, cold forming may be used on metal stock, sheet, bar, and rod stock. Cold
sizing can be performed on various metals, both ferrous and non-ferrous, and even materials
like polymers and plastics. Sizing is related to other squeezing operations like swaging,
coining, hobbing, staking and riveting, thread rolling, and extruding.
Although the whole work piece may be inserted into the die, the sizing operation can give
dimensional accuracy to a portion of the part based on the contact with the die. Sizing is mostly
used to give a forged or cast part better dimensional accuracy. Mated surfaces between
touching parts like gears are often sized. The sizing operation also provides a better surface
hardness and finish to the work piece. Also, the sized surface of the work piece gets denser and
stronger when the operation is performed. The dimensional tolerance of the operation is about
0.025 millimetres (0.00098 in). Primary pressing or a compacting die are typically used when
sizing small batches of compact. To keep costs down, larger batches of compact usually have
a specialized die made specifically for the operation.
1. Power % - 5-8 2. Heating time - 5±2 3. Dwell time - 0.5±0.25
Fig No. 4.37 Principle of Induction
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13. QUALITY GATE 2 Quality 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. .