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CONTENES 1.Acknowledgements 2.Certificate 3.HM- Company Profile 4.Introduction 5.Problem Definition &Initial Trials 6.Heat Treatment Process 7.

Fishbone Analysis 8.Conclusion

CERTIFICATE

THIS IS TO CERTIFY THAT MANISHA SURESH SONAR HAVE COMPLITED A PROJECT ON BENDING IN CLUSTER GEAR SHAFT ANALYSIS AND SOLUTION ; As a part of her training at A.V.TECH,LTD PITHUMPUR FROM - 5MARC 2013 TO 5 APRIL 2013AND HER PERFORMED SATISFACTORILY.

PROJECT GIDE N. K. RAO. D G M QARD, AVTECH LTD PITHUMPUR.,

ACKNOWLEDGEMENTS
I Would like to express my sincere gratitude towards Mr.N.K.Rao,(DGM,QARD)Hindustan Moters Limited,Pithampur for allowing me to undertaken this project.It has been an absolute pleasure to be associated with him.I think him for his constant guidance and enlightening insights during my short sojourn. I would also like to thank Mr.Prashant Sarvastava(HEAD,training Center)for this help.I am immensely indebted to Mr.D Ghoshal,Mr.S.SARAF and Mr.H. Srivastava (members of Heat Treatment Cell) for their guidance,support and continuous efforts without which the successful completion of this project would not have been possibal . In the end, Iwould like to express my gratitudetowards all the operators,security personnel and HR personal who have directly or indirectly contributed in my project wok.

HINDUSTAN MOTORS LTD. COMPANY PROFILE


Hindustan Moters Ltd.pioneers in the Indin Automobile sector is one of the G.P.Birla&C.K.Birla groups of companies.The company came into existences in 1942 at Port OKHA. Later the company was shifted to Uttara (W.B)near Kolkata.In1944-45 the company entered into collaboration with Nuffield Org. of England& started manufacturing Indian model of Moters cars. In subsequent years it kept on giving different models: viz Hindustan, Hindustan Land Master M, Hindustan Traveler, Hindustan Ambassador, mark 1to4, Ambassador Nova&Contessa 1to the Indin customers.

Various Divisions Of HM Name Yea Located Present Products div. r At Collabor Manufactured ators
Hind Moter Div

Power products Div Power Unit Div.

1942 Uttarpara, NONE West Bengal 1983 Hosur Allison,USA Tamilnadu Twin Disc,USA 1984 Indore Isuzu,japan M.P.

Passenger Car Power Shift transmission Diesel, Petrol & transmission for Ambassador& Contessa

Mitsubishi Lancer Car Motors Crop Engines& Japan transmissions Chennai 1997 Chennai Mitsubishi Lancer Car Car Plant Tamilnadu Motors Crop, japans RTV 1998 Indore OKA Motors M.P. Crop,Austral RTV ia manufacturing& assembling.

1997

Indore M.P.

THE POWER UNIT PLAt


The power plant of hml, which was initially the passenger car divisions was established in 1984 the division comprised of state of art manufacturing. The division complex, manufacturing fuel-efficient engines and transmission, basically for passenger car application the division spread over an area 153- hectare. The the total investment in the divisions including the machinery amounted to around s- 1840 million. The main Assimilation of technology from Isuzu Japan. The production in the division commenced from 1987. At present plant has manufacturing capacity of 15000 power unit per annuam. The division can boast of ultra modern research and development facilities for design can boat of ultra modern research and development facility for design, development and testing of engine and transmission. The division also caress out systematic training program and in 1995-1996 the division achieved 4 mans day of training per employee per year. During their journey owards excellence him, pithumpur got iso9001 accreditation in 1994, in addition to this they were certified as iso9001 accreditation in 1994. In addition to this, they were certified as Iso14001 Company for their environmental management system implementation in November 200. The journey for excellence system implementation in November 2000. The journey for the excellence continues with the effort in embracing total productive method as a religion with the effort in embracing total productive maintenances as a religion in addition to institutionalizing qs9000 standards.

Introduction by Hindustan motors ltd. KNOWN AS THE CLUSTER GEARS SHAFTS . YHE c.g.s. THE c.g.s IS A PART OF THE TRANSMISSION ASSEMBLY ASSEMLED IN H.M. LTD, PITHUMPUR FOR MAHINDRA AND MAHINDRA The focus of my project is a component manufactures BOLERO. THE MANUFACTURING PROCESS OF c.g.s. involves the following steps. 1- Forging- the shaft is forged at HMS uttarpara plant situated in west Bengal and sent to pithumpur for further processes. 2- Machining- the various machining operation that are carried out on the forged shaft are 1- facing and cent ring , 2- turning,3-thread cutting , 4gear hobbling & shaping, 5- splint rolling- , 6- gear shaving. All the above operation are carried out on cnc machine. 3- Heat treatment the heat treatment procesis is the most important step in the manufacturing of cluster gear shaft, since it is this stage which imparts the component the required strength need to withstand normal and terosinal stress of varying magnitude, to which it is subjected. This phase basically consist of the fooling step which have been discussed in detail since this is the main area of my study 1- carburizing and hardening, tempering. 4- Hard grinding- after the heat treatment process the cgs is sent for hard grinding. This is the final machining operation before the C.G.S. is sent for assembly. This stage ensures the desired surface finish on the component 5-

Heat treatment processThe fooling text contains a study of the process to which the cluster gear shaft is subjected in the heat treatment shop. The list of processes is under1- Prewashing 2- 2- carburizing and hardening, 3- 3- post washing 4- 4-tempering; 5- - shot blasting, 6- Straightening 7- Induction annealing. Prewashing this phase is carried out to free the component from oil, dust and any undesirable surface deposit. The process is carried out in a specially designed washing Mac to 1 hr to be complied. -carburizing & hardening- carburizing is the absorption and diffusion of carbon in to solid ferrous alloy by heating to a temperature usually above Ac3 fec diagram in contact with a suitable carbonaceous material gas carburizing uses CARBON FROM A HYDROCARBON GAS AND EASILY VAPORISED HYDROCARBON LIQUID O PRODUCE A HARD SURFACE on steel mpart . The main function of carburizing is to produce a hard surface layer on steel part. The main function of gas carburizing is to be providing adequate supply of carbon for absorption and diffusion into the steel. a common commercial practice is to use an endothermic gas is carrier that is enriched with one of the hydrocarbon gases the atmosphere inside the furnace is combustible and toxic while the medium reducing. Hardening means increasing the hardness by a suitable heat treatment process which involves heating the components above the austenising temperature for a certain pre-determined

1-

2-

3-

4-

5-

6-

period of time and then rapidly cooling it by quenching it in suitable the result obtain are unsatisfactory as far as he improvement in the value of bending in the cluster gear shaft is concerned, as percentage improvement in the result is almost negligible we may infer that the changing of oil has not shown any improvement in bending however the shaft cell reported an improvement in the lead profile which was positive sign. 4- priestesses- one of the causes of bending can be attributed to the pre-stress in the component developed during the additional stress during the machine stage. The forged components supplied the company not normalized as per the specification of the input material. As the component pass through various machining operation these stress are compensated during quenching in the from of bending and distortion. To prove the fact we conduct 2- trials in which the change was pre- heated to relive any forging or matching stress before being subjected to hardening and quenching the experiment was carried out on charge no 8192/8198 the preheating carried out in tempering furnace at a temperature of 500.dc, for a duration of 60min. the result of the trials are attached in the fooling pages D. METHOD- analysis these variable- i- time, temperature, and pressure- the time temperature for various processes is already specified on the process sheaf and is proved to be correct the prescribe time , temperature and pressure are mentioned on various machine the case depth and hardness values thus obtained are within specification. Quenching process- large bending stresses are generated during quenching since. The component at very high temperature 920 dc is suddenly cooled. The causes distortion in component, in earlier trials to study the effect.

78910111213-

Slow quenching was also done but this did not yield any encoring result, so was ruled out. Flow quenching oil into the f/c may have some effect on bending. So to get a uniforms flow over components, additional guard besides the fixtures was put inside the machine, even this did not produce any improvement in terms of reduced distortion so this factor was ruled as well. Quenching oil- one of the possible reason for increasing bending could be attribute to the quenching oil being used. in one of the earlier trials in conducted at hm , a step was taken to change the quenching oil altogether these the older mt-355 was replaced by an oil- vedol quenching hm, thus is more viscous than the former Ch no 5359 mt-355- oil charge qty-77 no. Range mm no of compo % remark. 0.00-0.06 18 23 good 0.17-0.10 18 23 fair 0.11-0.15 13 16 bad >0.15 28 36 very bad Visual case depth- 0.6-1.0 mm. microstructure- case- fine tempered mrtensite, no carbide network allowed. Retain austenite, 40% maximum, and core- low carbon tempered martensite lctm + bainite.

14151617181920-

Medium. Case hardening is generics term covering several processes applicable to steel that change the chemical composition of the surface layer by absorption of carbon,

21-

nitrogen etc. the process used for doing case hardening involves carburizing followed by quenching. Initial trials- we conducted 3 trials initially on charge numbers 8160,8162,8163 with a view to a- learn more about heat the treatment process under studys- get an insight into the nature of the problem and the variable concerning it . the result of the run outs observed on the cluster gear shafts in these trials have been attached in the subsequent pages they have been summarized as under. Trial 1 2 3 charge no 8160 8162 8163 no of components 77 77 77 Avg run out 0.17mm 0.147mm 0.15mm bad bad bad

THE AVERAGE RUNOUT AT SECTIONS A In cluster gear shaft of all 3 trials was found to be 0.155mm or 155 microns which is well above the specified tolerance of 0.04mm or 40micron. A runout of this magnitude required considerable prevent this problem occurring that the heat treatment stage.straighting action o brings the component within the specified limits. Which is not advisable? Since it may damage the shaft .hence it is of utmost importance to Note- it nuts be noted the forging applied to H.M. As against being normalized xcm318 harden and tempered forging of a required material is supplied. c- Jigging and fixtering- the fixture which the component mounted may be faulty the fixtures may have bends in themselves or the initial mounting may be incorrect, but the fixtures have been thoroughly cheacked for such inherent faults and any such possibility seen ruled out. Gauges /calibrations- various gauges on different machine are checked for performance. Monitored and calibrated on regular basis. Therefore this factor canbe ruled out as a possible cause of bending.

Condition of fixture- various possible activity is carried out observe no issue., furnace and heating pattern - one of the possible causes for large magnitude of distortions, / bending during heat treatment can be non uniform heating in sealed quenching furnace this result in to localize thermal stress which are ultimately compensated in bending. This fact had to be suited in depth so as to evaluate its validity. In the given context. We conclude three trials chq no 8163, 8192, 8198, and drew up location wise bending pattern for each charge. these pattern have been attached pages, when the pattern have been attained in the subsea pages, when these pattern were studied for any observable trends that indicated any discrepancy in the furnace heating pattern they did not revel any such trend thus we conclude that the furnace were functinating normally and the problem being discussed could not be the functioning normally and the problem being discussed could not be attribute to them. Problem definition- it has been observed that during the heat treatment process the cluster gearshift undergoes bending of the order of 150-200 micron. 0.15 to 0.25 mm. as against specified tolerance. Of 40 microns 0.04. a measurement of runouts of components before and after heat treatment process, illustrate this fact. These bending make it necessary for a large amount straightening operation to be carryout since apply high lod is not avlable and its twist and effect the component. Adversely hence it is very important that is bending remove, the cluster gear shaft is a critical component of the transimation assembly and any short case in its quality is reflected on the functioning of the entire unit./, our project task would be study the heat treatment process , they various factor concerning and affecting it, identifying the possible reason for bending and suggesting measure to eliminate it.

Summary of resultthe result of run out at section a 0f charge nos- 8192/8198 are summarized as below.

Trial 4 5

ch.no. 8192 8198

no of comp 47of 77 recorded 77

avg-runout 0.073mm 0.061

comment very good very good.

The average run out of stress relive cluster gear shaft was found to be 0.067 microns. In comparison to our initial trials where the avg run out 0.155mm, we see a 56.7% reduction in the run out. Section a As it is evident the next page which illustrate, it is worth nothing in the ch no 8198, sixe component 8198. Sixe components were such that they did not require any straightening action at all. These are very positive sign which were not observe earlier.

FISHBONE ANALYSIS
The fish bones analysis is done on the basis of four aspects that govern a components process of manufactures. As depicted in the diagram, the fishbone analysis for cgs is followsa- Man- loadingThe loading of components is performed by unskilled operators. Since before being loaded into the furnace, the arrangement is cross checked for correct loading style and pattern, thus the possibility of this fact being responsible for bending is ruled out.Further, if this was the reason responsible for increased bending than it would have been observed only in a few components which had been erroneously loaded, but repeated bending discards mishandling as a cause.

ii. Monitoring
Although most of the controls are electronic and automatic, but human supervision is essential to ensure problem free running of the process. If lack of monitoring had been the reason for increased bending then it would

have been observed only in a specific charge, but repeated patterns eliminate this as one of the probable causes of bending.

iii.STRAIGHTENING The straightening operation is one operation which relies heavily on the skill of the operator , but since the bending occurs before the operations i.e. during heat treatment hence these bending occurs before the operation i.e. during heat treatment hence these bending occur before these operation i.e. during heat treatment hence these bending cannot be attribute to these operation mistake can be made during measurement of run outs but practically this will not lead to error of the magnitude. But practically this will not lead to errors of the magnitude. b- Materialc- Composition- the material specification for cluster gear shaft is as follow material xscm318 low carbon alloy steel , input specification, annealed/ normalized 160/220 b.h.n out put specification- surface hardness 58 h.r.core hardness 30-45 hrc , effective case depth, 0.5-.8 mm. d- Fishbone digram:-

Material Composition loading

man

Straightinig monitoring Time/tmp/pressure Time/ temp/pressure pattern fixtures bending in c.g.s. sqf/c heating

Quenching process .quencing oil used

gauges

condition of machine

1- Every components is checked for the magnitude of distortion bending it has undergoes during heat treatment this is done by measuring run out at section a , c. b. , dial gauges with a least count of 0.01 mm i.e. 10 micron are employed for these a common trends has bents section that the run outs increases dia the run out is seen to be increasing , second step of straitening operation is to apply mechanical load on the bent section primarily section b & c to minimize the run out so that component fall within the specified tolerance the load is usually not applied on section a which being greater in cross section is susceptible to d damage. 2- These straightening machine used is based on hydraulics control and has been manufacture by galdabini Italy. The machine has max load capacity of 50 tons. But the maximum load during the straightening of cgs is kept 5 tons. It must be noted that he straightening operation is largely depends on the operators skills. It always advisable may handle the operations. 3- Induction annealing- the last operation on the cgs involves the localized heating in threaded portion of the mentioned area by means of electrical induction to a certain temperature followed by gradual cooling in air annulled is carried out to soften the threaded portion, the induction annealing machine has been made by ema- india.after induction annealing the component is sent for hard grinding before finally being dispatched for assembly. 4- Conclusion5- After studying the result of trials, we can conclude that stress reliving the components has yielded good result. Thid illustrate the fact that the component yielded extremely good result. The illustrates the fact that the components carry a large magnitude of machining stresses prior to heat treatment.

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