What is gear!

GEAR IS A TOOTHED WHEEL WHICH IS USED TO TRANSFORM POWER.

The processes driven in gear manufacturing

FORGING TURNING / FACE GRINDING BLANK INSPECTION HOBBING / SHAPING SHAVING HEAT TREATMENT SHOT BLASTING CENTRE CLEANING STRAIGHTING MARKING OUTER DIAMETER GRINDING INNER DIAMETER GRINDING WASHING OILING ASSEMBLY INSPECTION PACKING

Hard Machining Process

HOBBING:It is the very first machining process. In it we did teeth cutting on the job. The jobs material is 16 Cr Ni O4. The cutting material in hobbing machine is M-5.
Hobbing is done on LIEBHERR machine which is made in Germany and its model is LC-150.

The teeth cutting is done by the help of a coolant whose name is iolo cut 945.which is made by Castrol oil company.

SHAVING:It is the second process after teeth cutting after hobbing there are some burr on the hobbed material/job. To remove them we use shaving process. It is also used as finisher of the hobbed material.
Shaving is done on Mitsubishi machine which is made in Japan and its model is FE30A. The finishing of the material is done by the help of shell grain 405 M 22 cutting oil.

SHAPING:It is also a machining process. In it we also done teeth cutting but in this process the teeth cutting is done on shafts where the distance between teeths are very low. Shaping is done on LIEBHERR machine which is made in Germany and its model is LS-150.
The shaping process is done by the help of a coolant whose name is CASTROL GLYCOL REFRIGERMANT (CGR).

24 gp

16 fp

Heat Treatment Process

There are five basic steps & three secondary stepsBASIC STEPS Pre washing Pre heating Sealed quenching Post washing Tempering SECONDRY STEPS Center cleaning Straighting Marking

PREWASHING:In pre washing the job is warmed to 150C for 30 minutes by the help of water with the help of load table it is send to the pre heating furnace machine. PREHEATING:In pre heating the material/ job is warmed to 750C for 60 minutes by which the material is ready for the next process which is carburizing.

SEALEDQUENCHING:In this process the carburizing is done on 920C. In pre heating the percentage of carbon is 0.65% but after carburizing is becomes 0.95%. By the increasing in temp to 920C, the job become rough and there is some fractures on it to decrease the roughness as fractures we done the pre heating process. The pre heating & quenching is done by the help of LPG gas the next process is post washing.

POST WASHING:After carburizing the temperature of the job is 950C to cool the job we done post washing in it we take the jobs temperature to 120C by the help of water and ammonia. TEMPERING:Tempering is done for the removing of cracks which are becoming in the process carburizing.

Three Secondary Steps

Centre cleaning: - In it the jobs are washed by the help of water so the remaining carbon gets removed. Straighting: - If there are some bent after the carburizing, to remove the bent of job, we done straighting. It is done by the help of pressure. The straighting machine is work on the mechanical pressure.

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

D10E148 Where D means APRAIL (Month) Where 10 means 2010 (Year) Where E148 means batch no. & fixture no. This is done by the help of MARKMAN which is made in switerzerland and its model is MK-300.

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

deburring of the job. In it we through the bullets of steel of 0.8mm diameter at a very high speed. By the high speed the steel bullets are driven on the job so the deburring of the job get completed.
This process is done by shot blasting machine which is fully

covered by steel gates. This machine is made by Disa Engg. & its model is VP-14.238. This machine is made in INDIA.
After the shot blasting the job is sent for the grinding

because grinding process is done on hard material/job.

SOFT MACHINING
I/D GRINDING:- In I/D grinding we finishing the inner diameter

of the job. This process is done on PMT MACHINE. In the plant there are two types of PMT MACHINES FIG 100 FIGE 150 The I/D grinding is done by the help of coolant ( water + cutting oil ). O/D GRINDING:- In O/D grinding we finishing the outer diameter of the job. This process is done on JUNKER machine. The O/D grinding is done by the help of coolant ( Castrol Hyspin AWS 46 Hydraulic OIL ). By the help of JUNKER machine we can grinding of 10 diameters on a single piece and in a single time. The only drawback of JUNKER is that it takes about 2 minutes in a cycle. So its production rate is little low.

Job after soft machining

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

PRESSURE. This process is driven separately for shafts and gears.

ASSEMBLY- Assembly is the last mechanical process of the

gear plant. In it we assembles the gear by the help of SYSPAC GEAR ASSEMBLY M/C. This machine is made by an Austrian company named SYSPAC. These are two machines in the quantity.

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

GEAR ASSEMBLY