Training Report

Industrial Training from Bharat Gears Ltd.

Title of Project

Study of Pt No. 3621 -Spur Gear Manufacturing Terminology and

Improve Quality to ensure zero defect policy

BACHELOR OF TECHNOLOGY

Mechanical Engineering

Under the guidance of

Mr. Nehpal Singh

(Head of Department)

Submitted by

SAHIL SHARMA

(12-ME-124)

Department of Mechanical Engineering

Echelon Institute of Technology, Faridabad

Maharshi Dayanand University

Rohtak

May, 2016

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CANDIDATE'S DECLARATION

 I hereby certify that the work which is being presented in the report entitled “Study of Pt No 3621 -Spur Gear Manufacturing Terminology and Improve Quality to ensure zero defect policy,” by “Sahil Sharma,” submitted in the Department of Mechanical Engineering of Echelon Institute of Technology, FARIDABAD is an authentic record of my own work carried out during a period from 1st February 2016 to 31st May 2016 under the supervision of Mr. Nehpal Singh. The matter presented in this report has not been submitted by me in any other University / Institute for the award of any Degree/Diploma.

 

Signature of the Student

 

 This is to certify that the above statement made by the candidate is correct to the best of my/our

knowledge

  

Mr. Nehpal Singh

Production Department (HOD)

Bharat Gears Ltd.

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ACKNOWLEDGEMENTIt is a great pleasure for me to express my sincere gratitude to my head Mr. Nehpal Singh,

Department of Production in Bharat Gears Ltd. , for his valuable guidance, timely advice and

constant encouragement during the project work.

Dated: 1st May 2016 Name: Sahil Sharma

Roll No. : 12-ME-124

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Abstract

I have done my 4 months Industrial training at Bharat Gears Ltd located in Faridabad. In this period of 4 months I have been through various manufacturing departments but proficiently I have done major work on production and quality department. I started my training with the goal of learning almost every manufacturing industrial patrons and to gain explicit knowledge of all the gear terminologies.

In BGL, I have been through various activities which includes the inspection of receiving material, passing the raw material by Heat Treatment department, gear manufacturing from a blank to final product, passing by the BHT quality department, fulfilling the hardness requirement of customer through heat treatment processes, allowance of AHT quality department, final inspection with the goal to achieve a perfect quality and the packaging activities.

Due to this training I have perceived a good knowledge of measuring instrument like Contracer, Profile Projector, Coordinate Measuring Machine (CMM), Bevel Protractor, Hardness Rockwell Tester and also I am very much updated with Heat Treatment processes.

BGL is very much employee-friendly company. In this all the employees are arranged in a proper hierarchy with the worthy allotment of the work load. In shop floor there are the HOD's who always make an eagle vision over the working areas to ensure the zero defect policy. Also in BGL shop floor is provided with the proper arrangement of departments. It follows the sequential arrangement of department with the required need of material at that particular time. The sequence of shop floor is Receiving Area-Production-BHT quality-Heat Treatment-AHT quality-Grinding-Final Inspection-Packaging-Dispatch. Also if take into account the non-technical department like HR department, Mess & Canteen department, Time office department and the Security departments they all work with full dedication and always keen to give their full for the betterment of company.

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INDEX

INTRODUCTION

1. OVERVIEW2. MISSION & VISION3. OUR STRENGTH4. MANUFACTURING CAPABLITIES5. BUSINESS DIVISION

PROJECT DESCRIPTION

1. GEAR DATA2. METLLURGICAL DEPARTMENT3. RECEIVING INSPECTION4. PRODUCTION5. HEAT TREATMENT6. FINAL INSPECTION & DISPATCH

ANALYSIS

CONCLUSION

BIBLIOGRAPHY

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1. INTRODUCTION

Overview

Bharat Gears Ltd. (BGL) is one of the world leaders in gears technology and India's largest gear manufacturer. We at BGL bring to you the finest in gear and transmission technology. Our delivery expands to nations across Europe,USA, Mexico and Asia.

BGL is a major global supplier of automotive gears andheat treatment furnaces. The company manufactures awide range of Ring Gears and Pinions, Transmission Gears and Shafts, Differential Gears, Gear Boxes majorly for the automotive industry.

Our modern manufacturing facilities are located at Mumbra near Mumbai (Bombay), Faridabad near Delhi, capital of

. India and Satara near Pune.

In its relentless efforts to meet and exceed the needs and demands of its customers BGL has made rapid progress in international market. Leading OEM's like TATA Motors . New Holland Tractors, John Deere Equipment Pvt.Ltd.

(JDEPL), VST Tractors (Mitsubishi), Carraro, John Deere . Coffeyville Works , TMA, TDI and Tier I companies like Dana Corporation in USA and several others.

With both plants ISO/TS-16949:2009 Certified and Faridabad Plant ISO-14001:2004 certified also, BGL is internationally reputed for its cutting edge technology, established quality processes, and capabilities

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developed over the years. With customer satisfaction at the foundation of its entire operation, BGL isdedicated to maintain commitment.

Mission & Vision

To retain and reinforce our position as a leading Indian manufacturer of automotive gears and aggregates and meet the aspirations of customers in domestic and export markets. This will be achieved through on-time zero defect supplies backed by responsive service, empowered employees, vendor partner and satisfied investors.

We, the proud members of the BGL family, shall strive vigorously to delight our customers and stakeholders who are our very purpose, by pursuing excellence and innovation through committed team work. To this end we shall promote continuous learning, achievement orientation and ethical business practices, which will make us shine as a global player.

Our Strength

We believe that our historical success and future prospects are directly related to a combination of strengths, including the following :

Best ‘Speed to Market’ in Industry

Cost efficiency

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We are dedicated to achieving excellence in our work. Bharat Gears maintains the highest ethical and professional standards and strives to stay on the leading edge in technology, in an ever-changing environment.

While our greatest strength is the ability to understand the client goals, our success is very much attributed to strong teamwork, continuous R&D and the dedication and commitment of each and every member of the BGL family to deliver unsurpassed quality and reliable products & services to the total satisfaction of all our customers. 

World class technology

Global scale of operations

Product range and expansion lend scalability to operations 

Manufacturing Capabilities

Gear Manufacturing Heat Treatment Metallurgical Laboratory

Gear Manufacturing

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Heat Treatment

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We, the proud members of the BGL family, shall strive vigorously to delight our customers and stakeholders who are our very purpose, by pursuing excellence and innovation through committed team work. To this end we shall promote continuous learning, achievement orientation and ethical business practices, which will make us shine as a global player.

 

Continuous pusher type cycle annealers

Straightening

Induction hardening and annealing

Shot blasting / Hard shot peening

Manganese Phosphating equipment.

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Metallurgical Lab

Full range of hardness testers

Metallographic equipment

Automated Micro hardness testers

Raw material supplied by Steel Mill / Forge Shops is approved in advance and monitored. Process parameters, carburizing batch identification, testing variables are continuously recorded throughout the production process to ensure traceability and continuous monitoring of heat-treatment process.

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Business Division

GEARS

Ring Gears & Pinion

Transmission Gears & Shaft

Differential Gears

Gear Boxes

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FURNACES

SEALED QUENCH FURNACE LINES PUSHER CONTINOUS GAS CARBURISING LINES

BGL AUTOMOTIVE COMPONENTS

Transmission Gears Straight Bevel Parts

Steering Components Cover Assemblies

Differential Cage

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2.TRAINING DESCRIPTION

Pt No. 3621 Spur Gear Manufacturing Terminology

NO. OF TEETH 45

MODULE 4.233

HELIX ANGLE & HAND SPUR

PCD. 190.500

ROOT DIA 180.50±0.05

BASE CIRCLE DIA 179.011

FACE WIDTH 23.85

SAP 21.21

EAP 39.39

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GEAR DATA

The manufacturing of Pt No. 3621 Spur gear posses various operations and each operation is been through with various inspections to achieve the best quality for the complete customer satisfaction. The following are the steps which is followed for the complete manufacturing of part no. 3621 Spur gear along with all the inspection methods:

Metallurgical Department :In this department checking of raw material is done. The raw material as per the customer requirements is inspected and been through various processes.

Things I have learned :

Grain flow finding phenomena : Itching Cut Centre Apply Picric Acid Visual

Hardness Testing : Using instrument like Hardness Rockwell Tester, Brinell Hardness Tester and Vicker Hardness Tester

Carbon Percentage is 16.19

Zomney Testing: Sample from furnace-Zomney fixture-Appling water through nozzle

Heat Code is RA1618

Metal used 20MnCr5

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PROCESSES

1.Forger will buy the steel which going to be used for the forging of blank.

2.A sample of that steel will inspected in Metallurgical Lab.

3.A report will be made which consist of all the properties of that steel sample.

INSPECTION

Chemical Composition Inclusion Grain Size Zomney Hardenability Grain Flow Hardness Microstructure

2. Receiving Inspection

Things I have learned :

Use of Contracer in software FORMPAK for measuring minute angles precisely.

Use of Profile Projector to visualize the enlarge image of a gear profile.

Use of Slip gauge for measuring the width

Use of Bevel Protector for measuring angles.

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THINGS INSPECTED

1. Inner Diameter

2. Outer Diameter

3. Bore Diameter

4. Side Chamfer

5. Weight

6. Angle Variations

INSTRUMENTS USED

1. Vernier Caliper

2. Bore Gauge

3. Height Gauge

4. Slip Gauge

5. Bevel Protector

6. Contracer

7. Profile Projector

Production

Process Chart Of Pt No. 3621-Spur Gear

BROACHING : A key way is produce in the middle of blank.

HOBBING : Cutting of teeth take place in a hobber.

INITIAL ROUNDING : Rounding is done to remove the side sharp material.

FINAL ROUNDING : Complete rounding to give the finish on sides.

SHAVING : Teeth get shaved for the extra smoothness.

BHT INSPECTION : All the visual defects are done on BHT table.

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BROACHING

HOBBING

INITIAL ROUNDING

FINAL ROUNDING

SHAVING

BHT INSPECTION

Production Processes Image

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BROACHING HOBBING

ROUNDING SHAVING

Heat Treatment

FLOW CHART

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CHARGE PREPARATION

PRE WASHING

PRE HEATING

CARBURISING

QUENCHING

POST WASH

TEMPERING

SHOT BLASTING

Final Inspection & Dispatch

During final inspection piece is pass through various tests.

3.ANALYSIS

In the 4 months of training I have been thorough various experiences which indeed helped me a lot in learning and also taught me to get adjust in industrial environment. I have experienced

First-hand experience working as an engineering professional

Applied my technical knowledge and engineering methods to a real-life situations

Work with other engineering professionals

Experience what it’s like to work in a professional organization

Increased my technical, interpersonal and communication skills, both oral and written

Observe interactions of engineers with other professional groups

Witness the functioning and organization of business and companies

4.CONCLUSION

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ROLLING TEST

BORE TEST

PARALLELISM

OIL DIP

PLASTIC PACKAGING

BOX PACKAGING

BSR STORAGE

CONTAINER INSTALLMENT

DISPATCH

By doing the 4 months industrial training from Bharat Gears Ltd. I have gained a huge perspective of knowledge. Now I am very much familiar with the industrial terms moreover training also helped me in attaining discipline and punctuality in my life. During this training I made positive efforts to get knowledge of using instruments. Now I am also updated with all the gear terminologies which I had studied in college. Also I got know the areas where I am weak like designing and machine programming. I will make good efforts to overcome them.

5.BIBLIOGRAPHY

A special Heat Treatment class by Mr. Mahesh (HT supervisor) of two days from 26th-27th of April.

"Theory of Machine" by SS RATAN for all the specific knowledge of gear.

"Control Plans And Record Books" of BGL look after by Mr. KK Sharma(Production supervisor)

BGL Website http://www.bharatgears.com/

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