ID 327566

AN INTERNSHIP REPORT
ON

Submitted by
Harsh Pradipkumar Patel
190820119007
In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
In

Mechanical Department

Dr. Jivraj Mehta Institute of Technology, Mogar

Gujarat technological university, Ahmedabad

May 2023

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Dr. Jivraj Mehta institute of technology, Mogar

AY: 2022-23

CERTIFICATE

This is to certify that the project report submitted along with the project entitled
Elecon engineering company has been carried out by HARSH Pradipkumar
Patel under my guidance in partial fulfillment for the degree of Bachelor of
Engineering in Mechanical Engineering, 8th Semester of Gujarat Technological
University, Ahmadabad during the academic year 2021-22.

Manish Rohit VB.Senjaliya

Internal Guide Head of the Department

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COMPANY CERTIFICATE
Date: 9 May 2023

CERTIFICATE

This is to certify that Mr. HARSH PATEL who is a student of Under

graduate in stream of MECHANICAL Engineering at Dr. Jivraj Mehta Institute
of Technology is an engineering institute located, Anand, - 388340.
He is doing Industrial Training on following technology and Project till 3
months from Date of joining.

COMPANY NAME: “ELECON”

EXPERTICE IN: GEAR MANUFACTURING

Thanks and Regards,

V.B SENJALIYA
MANUFACTURING Manager
Elecon Engineering Co. Ltd.
Anand Sojitra Road Vallabh Vidyanagar – 388120 Gujarat, India.
CIN: L29100GJ1960PLC001082+91-2692-238 702 / 238 701 / 236 469 (GEAR)
+91-2692-237016 / 238 702 (MHE)infogear@elecon.com
(for Power Transmission inquiry)infoepc@elecon.com

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Dr. Jivraj Mehta institute of technology, Mogar

AY: 2022-23

DECLARATION

We hereby declare that the Internship report submitted along with the Internship entitled
Elecon engineering company submitted in partial fulfillment for the degree of Bachelor of
Engineering in Mechanical branch to Gujarat Technological University, Ahmedabad, is a
bonafide record of original project work carried out by me at Elecon engineering company
Gear unit under the supervision of V. B. senjaliya (external) and Manish Rohit(internal) and
that no part of this report has been directly copied from any student’s reports or taken from any
other source, without providing due reference.

HARSH PRADIPKUMAR PATEL

190820119007

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ACKNOWLEDGEMENT

I would like to express my thanks to Mr.Amit Patel And Mr.Vivek patel (Head of department)
Of DJMIT & I would also I sincerely express my deepest sense of hearty gratitude to the
following people for supporting and guiding me ahead in the journey of making the Internship
report of Industrial Summer Internship.
I express my profound gratitude and indebtedness to The Founder of “The Elecon
Engineeriring company” Iswarbhai B. Patel. I like to thank all the Professors of our college for
supporting & guiding me throughout our graduation.
I am also thankful to Mr. V.B. Senjaliya (Head of production Department) without their
guidelines and help I was not able to complete my Summer Internship. My heartiest thanks to
Mr.Mahesh parmar
Last but not the least, I express our deep feelings of love and affection to my beloved parents
for providing me valuable opportunities which helped me to stand out on my own feet this
stage.

Thank you…
Harsh pradipkumar Patel (190820119007)

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ABSTRACT

Industrial Internship Assess Interests And Abilities In The Field Of Study With
Incresing The Practical Knowledge And Experience By Developing Work Habits
And Attitudes Necessary For Job Success.
An internship was on the use of Manufacturing Process and Product . The main
objective Of This Internship in Elecon Engineering Company Ltd. is to study
of manufacturing Process in Mechanical engineering perspective. To compare the
different types of Product & Machine with the Mechanical engineering structures
and improve the Manufacturing.

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List of figures

Fig. 1.2.1………………………………………………………………………………………4

Fig. 1.2.2………………………………………………………………………………………5

Fig. 1.2.3………………………………………………………………………………………6

Fig. 1.2.4………………………………………………………………………………………7

Fig. 1.2.5……………………………………………..………………………………………..8

Fig. 1.2.6………………………………………………………………………………………9

Fig. 2.2.1……………………………………………………………………………………..14

Fig. 2.2.2………………..……………………………………………………………………17

Fig. 2.2.3………………………………………………………………………………..……18

Fig. 2.2.4……………………………………………………………………………………..18

Fig. 2.2.5……………………………………………………………………………………..18

Fig. 2.2.6……………………………………………………………………………………..19

Fig. 2.2.7……………………………………………………………………………………..19

Fig. 2.2.8……………………………………………………………………………………..19

Fig. 2.2.9……………………………………………………………………………………..20

Fig. 2.2.10……………………………...…………………………………………………….22

Fig. 2.2.11…………………………………………………………………………………….22

Fig. 2.2.12……………………………………………………………………………………23

Fig. 2.2.13……………………………………………………………………………………25

Fig. 4.1.1……………………………………………………………………………………..30

Fig. 4.1.2……………………………………………………………………………………..31

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Fig. 5.1.……….……………………………………………………………………………..31

Fig. 6.1.1……………………………………………………………………………………..31

Fig. 6.1.2……………………………………………………………………………………..31

List Of Tables

Table 1.1 Company profile.……………………………………………………………………1

Table 2.1.1 Work flow….……………………………………………………………………………...10

Table 2.2.1 Module…………………………………………………………………………………….11

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Table of Contents
Acknowledgement ..................................................................................................................................i
Abstract...................................................................................................................................................ii
List of Figures.........................................................................................................................................iii
List of Tables ..........................................................................................................................................iv
List of Abbreviations ...............................................................................................................................v
Table of Contents....................................................................................................................................vi

1.0 OVERVIEW OF THE COMPANY………………………………………..…………1

1.1 Introduction of the company…………………………………………………..……………………1
1.1.1 History………………………………………………………………………...……..……….1
1.1.2 Acquisitions and subsidiaries……………………………………………………..…………..2
1.2 Different products………………………………………………………………………........……..4

2.0 ABOUT DEPATMENTS………………………………………………….……..….…..10

2.1 Departments of the company………………………………………..…………………………….10
2.2 Work Flow In departments…………………………………………………..…………………...11
2.2.1 Gear project department…………………………………………………………….……….11
2.2.2 Planning……………………………………………………………………………..………14
2.2.3 Sales…………………………………………………………………………………………14
2.2.4 Design…………………………………………………………………………….…………16
2.2.5 Purchase……………………………………………………………..……….…….………..18
2.2.6 Workshop………………………………………………….…………………...……………19
2.2.7 Assembly…………………………………………………….……………...……………….20
2.2.8 Testing……………………………………………..…………………………….…………..23
2.2.9 Painting + Packing……………………………………………………….……………….…24

3.0 ABOUT INTERNSHIP……………………………..…………...………………………26

3.1 Aim of the an internship………………………………………………………………..……….…26
3.2 Objective of an internship…………………………………………………………..……………..27

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4.0 Methodology………………………………………………………………………….…….28
4.1 Process of macking gears…………………………………………………………….……………28
4.1.1 Cutting……………………………………………………………………………………....28
4.1.2 Broaching……………………………………………………………………..……………..28
4.1.3 Hobbing………………………………………………………………………….………….29
4.1.4 Gear shapper……………………………………………………………….………………..29
4.1.5 Milling or Grinding…………………………………………………………...……………..30
4.1.6 Machining……………………………..…………………………………………………….30

5.0 PROBLEM…………………….…………………………………………..………….…… .31

6.0 SOLUTION…………………….…………………………………………..………….…….34
7.0 BENIFITS…………………….…………………………………………..………...………..35
REFERENCE

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CHAPTER 1: OVERVIEW OF COMPANY

1.1 Introduction of the company

Elecon Engineering Company Limited is an Indian multinational company headquartered

in Anand, Gujarat. The company specializes in the manufacturing of industrial gear and
material handling equipment. Elecon is one of the largest Asian manufacturers of industrial
gears and material handling equipment for core major sector like power, steel, cement, sugar,
paper, mining, rubber and many more. Elecon group has subsidiaries such as Eimco Elecon
Ltd, Elecon Hydraulics, Elecon Information Technology Ltd (EITL) and Tech Elecon Pvt. Ltd.
(TEPL).

1.1.1 History
Elecon Engineering was established in 1951 in Goregaon, Mumbai by Ishwarbhai B. Patel.
The company’s early focus was on engineering, procurement and construction projects in India
and initially manufactured custom manufacturing conveyor systems. The company was then
registered as a Private Limited company on 11 January 1960.
In May 1960, the company moved to its current location in Vallabh Vidyanagar, Gujarat (now
part of Anand). Later, the company was listed on the Bombay Stock Exchange and the National
Stock Exchange.
In 1976, the company established its Gear Division, Specializing in power transmission
equipment and industrial gears. It designs and manufactures worm drives, helical gears,
planetary gears, couplings, loose gears, Custom built gearboxes and spiral bevel gears. Its
products target a range of industries, including steel rolling mills, wind turbines, marine
applications and space applications.
In 1995, Elecon established its Alternate Energy Division, for the design and manufacture of
wind turbines.
In 2012, Elecon Engineering secured two prestigious orders from the NTPC and Tecpro
Systems.

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1.1.2 Acquisitions and subsidiaries

Acquisition
In October 2010, Elecon acquired the Benzlers-Radicon Group, the power transmission
division of UK-based David Brown Ltd.

Subsidiaries
 Radicon Transmission UK Limited
 Elecon Singapore pvt. Limited
 Elecon Middle East FZE
 Benzler System AB -Sweden
 AB Banzlers -Sweden
 Radicon Drive System Inc. – US
 Banzlers Transmission A.S. – Denmark
 Benzlers Antriebstechnik G.m.b.h.
 Banzlers TBA B.V. -Netherlands
 OY banzlers AB-Finland
The Group of Companies
 Emtici Engineering
 Power Build Private Limited
 Vijay M. Mistry Construction Pvt. Ltd
 Modsonic Instruments Mfg. Co. (P) Ltd.
Associates
 Eimco Elecon (India) Ltd.

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Table 1.1 Company Profile

Type Public
Industry Manufacturing

Founded 1951; 72 years ago,

Founder Ishwarbhai B. Patel
Headquarters Anand, Gujarat
,
India

Area served Worldwide

Key people Prayasvin B. Patel
(chairman & MD)

Products Industrial gears

Material handling equipment
Mining equipment

Revenue ₹ 807.15 Crore

(US$115.3 million) (2021)

Net income ₹ 36.26 Crore

(US$5.1 million) (2021)

Website www.elecon.com

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1.2 Different products

Fig. 1.2.1

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Fig. 1.2.2

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Fig. 1.2.3

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Fig. 1.2.4

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Fig. 1.2.5

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Fig. 1.2.6

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CHAPTER 2: ABOUT DEPARTMENT

2.1 Departments of the company
Table. 2.1.1 Work flow

Gear project

Planning

Sales

Design

Purchase

Workshop

Assambly

Testing

Painting & Packing

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2.2 Work flow of department

2.2.1 Gear Project Department
The role of project department in any company is to provide guidance and
standards in the execution of projects. They create tangible goals, aligned with
the overall organization’s vision, and ensure all targets are met. Guidance comes
in the forms of project templates, standardized processes, education and
methodology recommendations.

2.2.2 Planning
Production planning is the process of deciding how a product or service will be manufactured
before the manufacturing process begins. In other words, it is how you plan to manage your
supply chain, raw materials, employees and the physical space where the manufacturing
process takes place.

Production planning is very important for manufacturers as it affects other important aspects
of their business such as:
1. Supply chain management
2. Production scheduling
3. Material requirements planning
4. Production lead time
5. Capacity planning

2.2.3 Sales
A sales department is responsible for selling products or services for a company. The
department comprises a sales team that works together to make sales, increase profitability and
build and maintain relationships with customers to encourage repeat purchases and brand
loyalty. If you’re a job seeker interested in sales, you may want to know more about the
functions of a sales department. In this article, we discuss sales department functions and the
objectives of a sales department, explain why the sales department is important in a company
and describe how to become a sales representative.
Different sales department functions employ various individuals to handle them. For example,
you can find the sales manager, sales development representative, account executive, sales
specialist and customer success representative in a sales department. All work together to
ensure the company makes sales. Some sales department functions are:

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1. Preparing sales plans

The sales department identifies sales goals and objectives and prepares a sales plan that acts as
a guide to achieving them. The goals usually include things like hitting sales quotas and
volumes. These goals tend to be short term. A sales plan includes details like the company’s
history, goals and objectives, team structure, target market, sales process, tools and resources.
Detailing the sales process is necessary when preparing a sales plan. A sales process comprises
steps that a sales team follows to identify leads to close deals. A well-structured sales process
improves conversions and closes deals. It also acts as a guide for sales representatives, which
helps them to provide unique experiences to prospects and customers.

2. Prospecting
The sales department is responsible for sourcing and identifying early-stage leads. Sourcing
involves online research on various sites, attending industry events or conferences or asking
for referrals from current clients or colleagues. When the department has identified the leads,
it takes them through the sales process by contacting them through cold calling, emails or other
means in an effort to qualify them for sales outreach.
A qualified lead Is an Individual Identified as a potential customer who meets specific business
requirements and is likely to move forward in the buyer’s journey. To determine this, the
salesperson uses data points, such as the prospect requesting a demo or quote, user interest,
buying intent, company size and the number of employees or roles within a company. Sales
development representatives are responsible for this step in the sales process.

3. Researching
After qualifying prospects, the next step for the sales representatives is to learn more about
them, including their pain points, to see how to align the benefits of the company’s products
and services to the prospects’ needs. This step increases the chances of them making a
purchase. The sales representatives research by asking the prospect specific questions or
speaking to others who work in the company to understand why they desire the products or
services and if it’s a priority.
Making sales
The department is responsible for bringing new business, pitching and closing a sales deal.
Individuals accountable for this process write proposals, create presentations or run
demonstrations to convince prospects to become customers. Due to the complexity of
demonstrations, the sales department reserves them for qualified leads. They make each
presentation suit each potential customer, according to their pain points and needs. When
prospects buy into their proposals, they negotiate the terms and close the deal. Account
executives are responsible for the success of this step.

4. Handling sales issues

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These sales issues could include answering complex questions from prospects or customers,
handling objections, resolving sales challenges or performing product demonstrations.
Individuals who handle these responsibilities are sales specialists. They’re professionals with
in-depth knowledge and experience of the sales industry and the products and services that the
company offers. Through the prospect’s questions and objections, they can align the
company’s products to fit the customer’s needs.

5. Building customer relationships

The sales team is also responsible for building and maintaining customer relationships. They
resolve their complaints, record complex issues and send them to the proper authorities for
addressing. They also renew subscriptions with existing customers. They identify other sales
opportunities and pitch to the customers for continued patronage and increased business
profitability. Excellent customer relationships lead to upsell and cross-sell sales opportunities
and referrals.

6. Training and onboarding

The sales manager organizes training and onboarding for newly recruited sales representatives
to train them on various sales methodologies. The training, which begins on the first day of
resumption, is a continuous process, as sales representatives learn new sales tactics regularly.
A trained sales team generates better sales results, resulting in huge returns for the business.

2.2.4 Design
“Design department is heart of any company.”
The role of design department is to design for manufacturing. Designing for Manufacturing
and Assembly (DFM or DFMA) is a critical part of the product development cycle. It involves
optimizing the design of your product for its manufacturing and assembly process, merging
the design requirements of the product with its production method. Employing DFM tactics
reduces the cost and difficulty of producing a product while maintaining its quality.
Around 70% of the manufacturing costs of a product can be derived from design decisions like
materials and manufacturing method. The remaining 30% of the costs make up production
decisions like process planning and tool selection. Focusing on design optimization reduces
the cost of manufacturing.
The struggle of hardware development comes from scaling from prototype to production.
Considering DFM from the beginning of the product development cycle reduces redesign
work, improves product quality, and speeds up your time to market.
Standardization cuts costs by reducing inventory and scale-up needs. Here are some ways to
think about part standardization:
 Design parts that can be reused within a product or shared between product lines.

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 Standardize your hardware within your products to reduce inventory needs.

 Make your designs modular to simplify product changes or redesigns.
 Use standard components instead of custom-made ones where you can.
Errors in alignment can damage parts or equipment, reducing yield or even causing line
shutdown. Tweak your designs to account for slop, misalignment, and tolerance stack up by
doing any of the following:
 Resolve assembly issues by analyzing how tolerances will stack up in your assembly.
 Design integrated part features to help with alignment during assembly.
 Add tapers or chamfers to guide components during assembly insertion steps.
The design department is provided with parameters. Throughout the parameters department
creates the isometric print. Showed in fig. 2.2.4

Fig. 2.2.1
This print also contains the steps of manufacturing and materials used for gear making.
The major material used in 14lecon are

EN353
The EN353 round bars, for example, have a lot of strength both internally and externally, and
when you combine that with the fact that they are suitable for numerous applications involving
elevated temperatures and the fact that it is highly wear-resistant, you’ll understand why this
is such a popular type of steel and why there are so many applications for it.
Table. 2.2.2 Composition of EN353
C Cr Mn Mo Ni Si
0.10-0.20% 0.75-1.25% 0.50-1.00% 0.08-0.15% 1.00-1.50%
0.35%
20Mn3Cr5

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20MnCr5 is a case-hardening steel with low carbon content but good hardenability reaching
good wear resistance due to high surface hardness after hardening. The small grain size benefits
in good ductility and fatigue strength. Suitable for gearboxes and axle gears.
Table. 2.2.3 Composition 20Mn3Cr5

C Cr Mn Mo Ni Si
0.17%-0.22% 1.0%-1.3% 1.10%-1.40% - - 1.15%-
1.40%

18CrNiMo7-6
18CrNiMo7-6 grade steel is an alloyed case hardening steel for heavy and high strained gear
parts with high demands on toughness at core.
It has tensile strength of 1050 – 1350 N/mm².
Alloy steel 18CrNiMo7-6 is a grade consisting of the addition of chromium, nickel,
molybdenum and coal with a range characteristic for all carburizing grades. 1.6587 materials,
unlike other simple steel grades, can be used for much larger sizes and loads. This grade of
steel is used for heavy-duty parts and components subjected to high pressures and highly
variable speed of operation. Materials and derivatives are used for the production of special
bearings, bolts, gears, shafts, or rack-and-pinions. They are related grades of steel according to
UNI standards, having slightly narrowed content of Chromium, Nickel and Molybdenum.
Table. 2.2.3 Composition of 18CrNiMo7-6
C Cr Mn Mo Ni Si
0.15%-0.21 1.50%-1.80% 0.50%-0.90% 0.25%-0.35% 1.40%-1.70% max
0.40

2.2.5 Purchase
The purchasing department of a company is responsible for procuring the goods, raw materials
& services required to operate the organization effectively.
Now, every organization has its specific needs when it comes to the sourcing and procurement
of equipment, raw materials, and services. These needs define the purchasing process and how
its purchasing department functions.
Based on these needs, an organization sets the purchasing department’s responsibilities and
streamlines its procurement plans to guard against demand-supply hurdles. Let’s understand
the role of a purchasing department in this process.
All purchasing department functions are aligned with the business objectives of an
organization. Here are some of the basic purchasing department functions:
 Identify business requirements for goods, materials, and services

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 Find reliable suppliers to meet these requirements

 Negotiate prices, build quality, and delivery terms
 Set up the order quantities and making bid requests on supply contracts
 Coordinate delivery and storage operations
 Run quality control and product testing
 Manage budgets based on ROIs and payments

Let’s explore the three main purchase department functions in detail.

 Acquiring Goods at the Best Possible Price
Purchasing departments must continuously evaluate materials based on quality and, more
importantly, on pricing! To maximize profitability, organizations need to procure goods
efficiently. For example, buying small quantities from a large vendor is not economically
practical. The procurement team must achieve bulk discounts on these orders and negotiate
with alternate vendors for better pricing.
 Procuring Raw Materials for Sustaining Operations
While procuring goods at the best price, the purchasing department must also maintain the
purchases necessary for sustaining daily operations. From raw materials such as iron and
plastic to machinery, production tools, and even office supplies - they all need to be procured
to keep the business running smoothly.

 Compliance with Industry Protocols

In addition to sustaining operations, all goods and services procured by the purchasing
department must also be compliant with industry standards and company policies. Vendors
should ensure that the raw materials are good in quality before delivering large orders. The
procurement department should also establish a specific purchasing policy that checks quality
compliance at every level of the purchase. But, before establishing any purchasing policy or
procedure, an organization must create a strong team of professionals specializing in supply
chain management.

2.2.6 Workshop
Workshop is a department where all mechanical operations is done. All the labor is taken in
workshop. Workshop of Elecon engineering company is divided into several other shop. The
shops are...
 Cutting shop
 Turning shop
 Gearcase machining shop

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 SB zone
 Hobbing shop
 Windmill shop
 Heat treatment shop
 Grinding shop

2.2.7 Assembly
Assembly is the process of combining individual components into a finished product during
manufacturing. An assembly may also refer to a single-level bill of material (BOM), a
multilevel BOM, or a top-level BOM. Assemblies may be comprised of mechanical, electrical,
or software components.
The company explained that the gearbox is made up of a number of segments, which are all
carburized to ensure a wear-free surface. Carburizing is a process whereby iron or steel is
heated in order to absorb more carbon, making the metal especially hard wearing.
Bearings are integrated into the planet gear to avoid common bearing failures and ensuring a
precise fitting. The planet stage transmits power produced by the blades.
Before assembly takes place, each component is measured against design specifications. Each
part is washed several times before it is put in place.
Once assembled, the gearboxes are tested with a full load to check for vibration and noise
behavior. This is done by placing a second gearbox back-to-back with the first to put the load
on.
Heaters, sensors and electrical systems are placed on the gearbox after it has been fully
assembled and painted.
Here some steps to assemble the 3MW gearbox
 Cleaning surface and make it wear free.

Fig.2.2.2

 Bearings are integrated into the planet gear.

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Fig.2.2.3

 The planet stage transmits the power produced by the blades

Fig.2.2.4

 Each component is measured before assembly to make sure it meets design

requirements.

Fig.2.2.5

 Gearboxes are then tested with a full load to check for vibration and noise behavior.

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Fig.2.2.6

 Sensors, heaters and other electrical components are attached.

Fig.2.2.7

 A complete 3MW gearbox.

Fig.2.2.8

 An exploded view of a gearbox.

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Fig.2.2.9

The time to assemble the whole gearbox is whole 3 days. After assembly it is tested for any
kind of damages and sends for painting.

2.2.8 Testing
Methods for Inspecting a Gearbox
 Visual walkaround
 Inspect magnetic debris collectors
 Visual inspection through inspection
ports  On-site analysis of lubricant
 Borescope inspection  Laboratory analysis of lubricant
 Measure temperature  Magnetic particle inspection of gears
o Thermometers  Dye penetrant inspection of gears
o Resistance temperature  Documenting gear condition
detector (RTD) probes
o Written
o Thermography
o Sketches
 Measure oil pressure
o Photography
 Measure sound and vibration
o Contact patterns
 Inspect filter elements

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2.2.9 Painting + Packing

the gearbox is vital for your operations, so it is essential that this equipment is manufactured
and maintained by a professional service company. From the components within the unit to the
paint on the outside, each element must be completed to the highest quality standards. It is
important to understand the purpose of cleaning the gearbox before it is painted and what a
quality paint can do for a gearbox.
Cleaning the gearbox before painting
Before painting, each gearbox is thoroughly sandblasted to remove all traces of old paint, oil,
salt, grease, corrosion, and any surface contaminants that may be present. This process prepares
the surface to accept a fresh coat of paint and guarantees that the finished coat will adhere to
the gearbox.
Cleaning and then painting the gearbox creates a more durable, longer lasting finish. Surface
preparation is the first step, and if it is not done correctly, then all the following steps cannot
be done correctly. It is important that each component is carefully inspected before painting to
make sure that nothing is missed during the preparation process.
Quality paint for a gearbox
One of the best paints to use on a gearbox is a marine grade epoxy paint. This type of paint can
provide long-term protection, without hindering the mechanical operation of your equipment.
Both the exterior and interior of the equipment should be coated with this paint. Painting both
the inside and the outside protects against any moisture or foreign elements that may seep into
the gearbox.
The marine grade epoxy paint also provides a high degree of protection against physical
damage from tools and other objects that may impact the surface. Once dried, the coating helps
protect the gearbox from nicks, dings, scratches, and dents. The paint also prevents immediate
equipment failure and rusting that can slowly damage or destroy the unit. Even the smallest
scratch on the surface can present an opportunity for corrosion to take hold, so having a reliable
paint on your gearbox is essential.
Marine grade epoxy paint has many properties that make it ideal for use within cooling tower
operations. These features include a strong adhesion to the surface, superior resistance to water
penetration, and minimal susceptibility to moisture during the curing process. Quick curing
minimizes the possibility of dust and debris infiltrating before the paint has dried. This type of
paint also offers reliable abrasion resistance once cured.
Painting scheme of Elecon
The painting on gear box provides surface protection as well as aesthetics on gearbox.
Elecon provides two types of paints. Although the official color is marine blue the thickness is
different. There are two types of thickness considering the usage. Heavy duty gearbox needs

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perfect and thick paint. So, for the heavy-duty gear boxes 185mm thickness paint will be
applied and for simple usage 145mm paint will be applied.
Packing of the gears
The most convenient and secure way to transport a gearbox is within its own crate or flight
case. This way it is easy to handle for postage and the gearbox is protected against damage
during shipping. If that is not possible, then the gearbox should be removed from its enclosure
and packed in a secure container for delivery. When sending gearboxes, it is important to
include a description of the contents and the serial number of the unit. Include the weight and
dimensions of the shipment as well as the original purchase order number and the customer’s
name and postal address.

Generally, gearbox from Elecon transported in wooden enclosure.

Fig.2.2.10

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CHAPTER 3: ABOUT INTENSHIP

3.1 Aim of the internship
An internship is a professional learning experience that offers meaningful, practical work
related to a student’s field of study or career interest. An internship gives a student the
opportunity for career exploration and development, and to learn new skills. It offers the
employer the opportunity to bring new ideas and energy into the workplace, develop talent and
potentially build a pipeline for future full-time employees. A quality internship:
 Consists of a part-time or full-time work schedule that includes no more than 25%
clerical or administrative duties.
 Provides a clear job/project description for the work experience.
 Orients the student to the organization, its culture and proposed work assignment(s).
 Helps the student develop and achieve learning goals.
 Offers regular feedback to the student intern.
Internships are supervised, structured learning experiences in a professional setting that allow
you to gain valuable work experience in a student’s chosen field of study. Internships require
a minimum of 120 hours (typically, at least 10 hours per week during the fall and spring and
either part-time or full-time during the summer).
Student Interns Expect:
 To gain real work experience and provide meaningful assistance to the company. They
don’t want to be gophers!
 To have a mentor who provides guidance, feedback, receptiveness and models
professionalism.
 To gain experience and skills in a particular field.
 To develop professional contacts.
 To gain exposure to upper management.
 To receive an orientation to the company for which they are interning. This introduces
the student to the company’s mission and goals and provides them with information
about company rules, regulations and procedures. It also introduces the intern to fellow
employees who they can go to in the future with questions.

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Benefits of Hiring an Intern:

 Ease workload of regular employees
 Enable employees to focus on higher level tasks
 Meet short-term staffing needs
 Complete “Priority C” tasks/projects
 Utilize a cost-effective employment strategy
 Obtain access to highly motivated students who can fill staffing needs
 Complete finite projects
 Develop a pipeline of future employees
 Prepare tomorrow’s workforce
 Inject enthusiasm and fresh ideas into your organization
 Provide practical learning opportunities to students
 Take advantage of students’ tech and social media savvy

3.2 Objective of an internship

Internships provide students with an opportunity to put into practice skills they have learned
while in school. In addition, students should have an opportunity to enhance those skills, obtain
the perspective of a work environment and benefit from a mentor or supervisor’s experience
and advice. To gain maximum benefit, the work experience must have a supervisor or mentor
available to provide coaching and evaluation of the student. Before the internship begins,
student and supervisor, with approval of your Faculty Coordinator, should develop several
learning objectives to be met during the work experience.
Objectives are views as outcomes. In other words, what do you expect to learn or experience
during your internship. Objectives are not tactics. In other words, objectives are not a punch
list of tasks to be performed. Tactics should be listed for each objective. Each tactic should
advance the particular objective it supports.

A trial runs
One of the main objectives of an internship is to expose you to a particular job and a profession
or industry. While you might have an idea about what a job is like, you won’t know until you
actually perform it if it’s what you thought it was, if you have the training and skills to do it
and if it’s something you like. For example, you might think that advertising is a creative
process that involves coming up with slogans and fun campaigns. Taking an internship at an
advertising agency would help you find that advertising includes consumer demographic

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research, focus groups, knowledge of a client’s pricing and distribution strategies, and media
research and buying.

Resume Building
When you apply for jobs, the more experience and accomplishments you have, the more
attractive you’ll look to a potential employer. Just because you have an internship with a
specific title or well-known company doesn’t mean your internship will help you land a nice
gig. Make an impact where you work by asking for responsibility and looking for ways to
achieve accomplishments. Be willing to work more hours than you’re required and ask to work
in different departments to expand your skill set. Don’t just fetch coffee, make copies and sit
in on meetings, even if that’s all it will take to finish your internship.

Network Contacts
Another benefit of an internship is developing business contacts. These people can help you
find a job later, act as references or help you with projects after you’re hired somewhere else.
Meet the people who have jobs you would like some day and ask them if you can take them to
lunch. Ask them how they started their careers, how they got to where they are now and if they
have any suggestions for you to improve your skills.

Potential Job
If you like your internship, you have the opportunity to excel and possibly land a job with the
company. Employers have an easier time hiring a person they know because they can get a feel
for that person’s work ethic, skills, creativity, ability to work with others and overall fit with a
company. Do more than you’re required to do, learn the office politics and make friends with
key people to increase your chances of landing a job with the company.

Learning objectives
Learning Objective 1: Learn case management functions and roles

Learning Objective 2: Learn how to effectively work with adolescents and emerging adults
facing crisis
Learning Objective 3: Learn how to enhance awareness of social service programs and duties

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CHAPTER 4:METHODOLOGY
4.1 Processes of making gears
4.1.1 Cutting
Gear cutting is any machining process for creating a gear. The most common gear-cutting
processes include hobbing, broaching, milling, grinding, and skiving. Such cutting operations
may occur either after or instead of forming processes such as forging, extruding, investment
casting, or sand casting.
Gears are commonly made from metal, plastic, and wood. Although gear cutting is a substantial
industry, many metal and plastic gears are made without cutting, by processes such as die
casting or injection molding. Some metal gears made with powder metallurgy require
subsequent machining, whereas others are complete after sintering. Likewise, metal or plastic
gears made with additive manufacturing may or may not require finishing by cutting,
depending on application.

4.1.2 Broaching
Broaching is a machining process that uses a toothed tool, called a broach, to remove material.
There are two main types of broaching: linear and rotary. In linear broaching, which is the
more common process, the broach is run linearly against a surface of the workpiece to produce
the cut. Linear broaches are used in a broaching machine, which is also sometimes shortened
to broach. In rotary broaching, the broach is rotated and pressed into the workpiece to cut an
axisymmetric shape. A rotary broach is used in a lathe or screw machine. In both processes the
cut is performed in one pass of the broach, which makes it very efficient.
Broaching is used when precision machining is required, especially for odd shapes. Commonly
machined surfaces include circular and non-circular holes, splines, keyways, and flat surfaces.
Typical workpieces include small to medium-sized castings, forgings, screw machine parts,
and stampings. Even though broaches can be expensive, broaching is usually favored over
other processes when used for high-quantity production runs.
Broaches are shaped similar to a saw, except the height of the teeth increases over the length
of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for
semi-finishing, and the final one for finishing. Broaching is an unusual machining process
because it has the feed built into the tool. The profile of the machined surface is always the
inverse of the profile of the broach. The rise per tooth (RPT), also known as the step or feed
per tooth, determines the amount of material removed and the size of the chip. The broach can
be moved relative to the workpiece or vice versa. Because all of the features are built into the
broach, no complex motion or skilled labor is required to use it.[2] A broach is effectively a
collection of single-point cutting tools arrayed in sequence, cutting one after the other; its cut
is analogous to multiple passes of a shaper.

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Fig. 4.1.1 Example of broached gear

4.1.3 Hobbing

Hobbing uses a hobbing machine with two skew spindles. One spindle is
mounted with a blank workpiece and the other holds the hob. The angle between
the hob's spindle (axis) and the workpiece's spindle varies depending on the type
part being manufactured. For example, if a spur gear is being produced, the
spindle is held at the lead angle of the hob, whereas if a helical gear is being
produced, the held at the lead angle of the hob plus the helix angle of the helical
gear. The hobbing features for gears are straight, helical, straight bevel, face,
crowned, worm, cylkro and chamfering. The speeds of the two spindles are held
at a constant proportion determined by the number of teeth being cut into the
blank; for example, for a single-threaded hob with a gear ratio of 40:1 the hob
rotates 40 times to each turn of the blank, producing 40 teeth in the blank. If the
hob has multiple threads, the speed ratio is be multiplied by the number of threads
on the hob. The hob is then fed up into the workpiece until the correct tooth depth
is obtained. To finish the operation, the hob is fed through the workpiece parallel
to the blank's axis of rotation.
Often during mass production, multiple blanks are stacked using a suitable fixture
and cut in one operation.
For very large gears, the blank may be preliminarily gashed to a rough shape to
make hobbing more efficient. Hobbing machines, also known as hobbers, come
in many sizes to produce different sizes of gears. Tiny instrument gears are
produced on small table-top machines, while large-diameter marine gears are
produced on large industrial machines. A hobbing machine typically consists of
a chuck and tailstock to hold the workpiece, a spindle to mount the hob, and a
drive motor.

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Fig. 4.1.2 Horizontal hobbing machine

For a tooth profile which is theoretically involute, the fundamental rack is straight-sided, with
sides inclined at the pressure angle of the tooth form, with flat top and bottom. The necessary
addendum correction to allow the use of small-numbered pinions can either be obtained by
suitable modification of this rack to a cycloidal form at the tips, or by hobbing at a diameter
other than the theoretical pitch. Since the gear ratio between hob and blank is fixed, the
resulting gear will have the correct pitch on the pitch circle but the tooth thickness will not be
equal to the space width.
4.1.4 Gear shaper
A gear shaper is a machine tool for cutting the teeth of internal or external gears, it is a
specialized application of the more general shaper machine. 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. However,
number of cutting teeth must be less than that of the gear to be cut for internal gears. For
external gears the number of teeth on the cutter is limited only by the size of the shaping
machine.
The principal motions involved in rotary gear shaper cutting are of the following:
1. Cutting Stroke: The downward linear motion of the cutter spindle together with the
cutter.
2. Return Stroke: The upward linear travel of the spindle and cutter to withdraw the cutter
to its starting position.
3. Indexing Motion: Slow speed continuous rotation of the cutter spindle and work spindle
to provide circular feed, the two speeds being regulated through the change gears such
that against each rotation of the cutter the gear blank revolves through n/N revolution,
where "n" is the number of teeth of the cutter, and "N" is the number of teeth to be cut
on the blank.

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4. Completion of Cutting Operation: The indexing and reciprocating motions continue
until the required number of teeth to the required depth are cut all along the periphery
of the gear blank.

4.1.5 Milling or Grinding

Spur may be cut or ground on a milling machine or jig grinder utilizing a numbered gear cutter,
and any indexing head or rotary table. The number of the gear cutter is determined by the tooth
count of the gear to be cut.
To machine a helical gear on a manual machine, a true indexing fixture must be used. Indexing
fixtures can disengage the drive worm, and be attached via an external gear train to the machine
table's handle (like a power feed). It then operates similarly to a carriage on a lathe. As the
table moves on the X axis, the fixture will rotate in a fixed ratio with the table. The indexing
fixture itself receives its name from the original purpose of the tool: moving the table in precise,
fixed increments. If the indexing worm is not disengaged from the table, one can move the
table in a highly controlled fashion via the indexing plate to produce linear movement of great
precision (such as a vernier scale).
There are a few different types of cutters used when creating gears. One is a rack shaper. These
are straight and move in a direction tangent to the gear, while the gear. They have six to twelve
teeth and eventually have to be moved back to the starting point to begin another cut.

4.1.6 Machining
Machining is a process in which a material (often metal) is cut to a desired final shape and size
by a controlled material-removal process. The processes that have this common theme are
collectively called subtractive manufacturing, which utilizes machine tools, in contrast to
additive manufacturing (3D printing), which uses controlled addition of material.
Machining is a part of the manufacture of many metal products, but it can also be used on other
materials such as wood, plastic, ceramic, and composite material. A person who specializes in
machining is called a machinist. A room, building, or company where machining is done is
called a machine shop. Much of modern-day machining is carried out by computer numerical
control (CNC), in which computers are used to control the movement and operation of the
mills, lathes, and other cutting machines. This increases efficiency, as the CNC machine runs
unmanned therefore reducing labor costs for machine shops.

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Machining operations
The three principal machining processes are classified
as turning, drilling and milling. Other operations falling into miscellaneous
categories include shaping, planning, boring, broaching and sawing
 Turning operations are those that rotate the workpiece as the primary
method of moving metal against the cutting tool. Lathes are the principal
machine tool used in turning.
 Milling operations are operations in which the cutting tool rotates to bring
cutting edges to bear against the workpiece. Milling machines are the
principal machine tool used in milling.
 Drilling operations are those in which holes are produced or refined by
bringing a rotating cutter with cutting edges at the lower extremity into
contact with the workpiece. Drilling operations are done primarily in drill
presses but sometimes on lathes or mills.
 Miscellaneous operations may not be strictly machining, in that they may
not produce swarf, but are still performed at a typical machine
tool. Burnishing is an example; it produces no swarf but can be performed
at a lathe, mill, or drill press.

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CHAPTER 5:PROBLEM

 The waste of lubrication

• the cost of lubrication/cooling systems represents between 7.5 and 17% of

the total gear manufacturing costs, compared with 4% of the tool costs
• in machining of difficult-to-cut materials, as the use for coolant, disposal and
the cleaning of the pieces lead to major costs, four times more expensive
than that of producing a gear.

• Cutting fluid purchase cost.

Fig. 5.1.1

• Workpiece cleaning and secondary operations costs to

remove the lubricant film from the surface and avoid

contamination between different manufacturing process

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• water used for cleaning the workpiece and the system itself should also be
considered. This cost can vary greatly depending on the water quality
required.
• Energy costs. Therefore, it is very important the proper selection of the
lubrication/cooling system to improve the energy demand of the

manufacturing process.

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CHAPTER 6: SOLUTION

 As 3D gears which can be made by 3D printer can be effective which

reduces the cost of the material wastage and which majorly saves the money
of lubrication which can be reduced

Fig. 6.1.1
 The use of 3d metal printer for manufacturing is like one time investment for
bringing that machinery.
 As the material like alloy can be used as filament for manufacturing a gear
with less waste
 The heating is not available in this process where the collect oil can be saved
at a major profit.

Fig. 6.1.2

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CHAPTER 7: BENEFITS

 As 3D gears which can be made by 3D printer can be effective which

reduces the cost of the material wastage and which majorly saves the money
of lubrication which can be reduced
 Cost reduction

 For any business, costs reduction is important and one of the advantages of
3D metal printing is that it will help to bring those costs down.

 Material costs

 The range of metal 3d printer filaments used for 3D printing is growing and
this makes it possible for the price to decrease

 These filaments are made up of alloy type materials

 Which makes the product maintain a good strength.

 Less waste

 Alloy materials, for instance, can be melted, cured (cooled down such that
they become solid), melted again, cured again, and so forth. Therefore
manufacturing ‘waste’ can be reused (thus preventing it from becoming
“waste” in the first place).

 The ability to reduce the time of the prototyping phase, businesses

can deliver better, improved and enhanced products in a shorter
space of time.

 Quickly designed reliable gears to meet customer demands.

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CHAPTER 8: CONCLUSION

 In conclusion, the web application development internship

experience has been an invaluable learning opportunity.
 I acquired real-world experience creating a good bond during my
internship utilizing a variety of technologies and tools.
 I also gained knowledge about the value of strong teamwork,
communication, and project management abilities in the process.
 These features offer an all-inclusive response to the different
business management issues that organizations are now dealing
with.
 In addition to assisting me in developing my technical abilities,
the internship gave me the chance to work in a professional
setting and made me realize the value of communication,
teamwork, and time management.
 My knowledge and abilities have grown as a result of this
experience, which has also equipped me knowledge. In
conclusion, the internship has been a difficult yet gratifying
experience that has advanced my professional and personal
growth.

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REFERENCES
 WEBSITES :
Link 1: www.google.com
Link 2: www.wikipedia.com
Link 3: www.shareinfo.com

Books
A guide to international trade and export management By: C.A VIRENDRA K
PAMECHA
Anti-dumping law & procedure By: R.K Gupta

"About Us". Elecon Engineering Company Limited. Archived from the

original on 11 November 2011. Retrieved 30 December 2011.
1. ^ "Elecon set to acquire Benzlers Radicon Group from David Brown Gear
Systems". Machinist.in. 29 October 2010. Retrieved 30 December 2011.

2. ^ "Radicon Joins Asian Market-Leader in Industrial Transmissions".

Radicon. November 2010. Archived from the original on 28 October 2011.
Retrieved 30 December 2011.

3. ^ "Elecon Engineering Group acquires UK based Benzlers-Radicon Group".

Elecon Engineering Company Ltd. 28 October 2010. Archived from the
original on 22 February 2012. Retrieved 30 December 2011.

4. ^ "Elecon Group Companies | Elecon". elecon.com. Retrieved 17

August 2021.

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