REDUCTION IN INHOUSE REJECTON OF FRONT AXLE BEAM

INTRODUCTION

TML Drivelines Limited was established on March 13, 2000 as a subsidiary of Tata Motors by
taking over operations of Tata Motors' erstwhile Axle and Gearbox Divisions. It is currently the
market leader in medium and heavy commercial vehicles axles in India with an installed capacity
of over two lakh axles per annum. The Company's product range includes Front Steer axles -
both live and normal, Rear Drive axles and dummy/ trailer axles. It is the leading supplier of
M&HCV axles to the Jamshedpur and Lucknow plants of Tata Motors.

It has state-of-the-art manufacturing facilities for making all major axle components such as
Front Axle Beam, Stub Axles, Front & Rear Wheel Hubs, Differential, Axle Gears (Crown
Wheel, Pinion, Bevel Gear & Shaft Gear), Banjo Axle Beam, Swivel Heads, Constant Velocity
Shafts etc. The Quality System of TML Drivelines Limited is certified under ISO/ TS-16949. On
the environmental and safety front, it received OHSAAS-18001 in 1999 and ISO 14001
certification in 2004.

TML Drivelines Limited has proven skills in manufacturing axles from component level to
assembly & testing. As one of the most modern forging set-ups in the country, the Forge is
equipped with the 40,000 mkgBeche Hammer and state-of-the-art presses from Kurimoto of
Japan. It produces critical forgings like crankshafts, front axle beams and rear axle shafts. The
Forge has been certified as ISO 9002 and QS 9000 by the BVQI.

While making technological, product and service advancements, Jamshedpur Plant has been
deeply committed to the communities among which it operates. Working closely with various
NGOs, it has pioneered initiatives in Health, Education, Livelihood and Environment. These
initiatives have resulted in significant progress in community and social forestry, sustainable
development of wastelands, road construction, rural health and education, development of rural
industries, water supply and family planning. A signatory to the UN Global Pact, it also takes
various initiatives in human rights protection, labour standards, environmental issues, modern
effluent treatment facilities, sanitation drives, soil and water conservation programmes, tree
plantation drives etc.

FORGING INTODUCTION AND TECHNIQES

The manufacture of forged products is fundamentally a process of forming metal, under impact
or pressures to economical products a desire shape with improve the mechanical properties. This
controlled plastically deformation, generally preformed hot is accomplished by any several
forging method all basically related to hammering and pressing.
Forging technique is extremely important in the entire machine building industries,
manufacture of automobile, machinery and equipments for ships, machine tools, railway engines
and milling stock Etc.

Forging improves the physical properties of metals by elongations, aligning and

compacting the grains of the metals. This in turn improves their mechanical strength. In the
hammer forging, the deformation of metal is the achieved by the force of impact, while in press
forging.
There are two Forging techniques-
1.Open die Forging
2.Close die Forging
Forging Equipments:-In the earliest time the forging is done by the black smith with the help of
different types of hammers and Tongs. For forging it is necessary to know about the forging
equipments. There are several categories, which are follows as:
Energy Restricted Machines
Stroke Restricted Machines
Load Restricted Machines

CHARACTERISTICS OF FORGING EQUIPMENTS

Energy restricted machines:- In the Energy or work restricted machines the deformation
energy is derived from the kinetic energy of a moving body or bodies. During a forging blow
deformation of the work piece continues until all the available energy is used further deformation
can be accomplished by striking further blows.
Stroke restricted machines:- Stroke restricted Forging machines derive their initial drive
from a rotating eccentric mechanism which imparts linear movement to a ram by means of
connecting device.
During deformation the load builds up until the ram pass through a
bottom dead centre Position. In such machines forging in a given impression must be
completed in a single blow.
Load restricted machines:-The hydraulic press is a load restricted machines since the
maximum load can be developed at any position within the available stroke. The maximum load
which can be sustained depends on the oil pressure in the cylinder whilst the speed of ram travels
is dependent on the rate at which oil can be supplied to the hydraulic cylinder.

CLASSIFICATION OF FORGING MACHINES

Energy Restricted Machines Stroke Restricted Machines Load Restricted Machines

Hammers (All Types) Crank and Eccentric Presses Hydraulic Presses
Friction Screw Presses Knuckle-Joint Presses Orbital Presses
HERF Machines Wedge Presses
Horizontal up setters

AUTOMATIC FRONT AXLE BEAM FORGING LINE

COUNTER BLOW HAMMER
 This line is presently being used for manufacturing for FRONT AXLE EAM (1312, Lift
axle Beam, Y1 7.5 ) On the TATA Vehicles. It consists of a Induction furnace which is charged
with cut billet (100RCSX1365) & billet wt.- 106kg continuously into furnace heating (1200+/-
50°c) for rolling then bending &rehetting (1250+/-50°c) from the induction furnace. From this
furnace material taken through a scale break or de-scalar and go to the Counter Blow Hammer.
After that the product passed to trimming. After trimming operation the finished forge Front
Axle Beam pass to cooling and hot inspection area.

Introduction and Process Sheet for Producing

FRONT AXLE BEAM
Front axle beam is one of the main components of automobile field; this is connected to
the Stub axle. Stub-axle is the forging of alloy steel containing chromium and molybdenum.
Stub-axle turns on the king pin; this is a light drive, fit in the axle beam eye located by taper
cotter pin, or some similar arrangement. Stub-axle consists of kingpin bosses, flange, shank and
straddle milling zone. It should be strong enough to absorb shock loads due to uneven road
surface. In industrial engines alloy steel with ultimate tensile strength of 90-105 kg/mm2 is used.
After forging the surface of stub axle is shot blasted and machined.

Flow Chart to Produce Front Axle Beam (Process Sheet)

RECEIVING BAR/BILLET
INDUCTION HEATING FURNCAE
ROLLING
BENDING
REHEATING
FORGING
TRIMMING
COINING
HEAT TRAETMENT
FINISHING & PARTING LINE GRINDING
SHOT BLASTING
SETTING
GRINDING
CRACK TESTING
PAINTING
STORAGE
DISPATCH
Material of Front Axle Beam
FRONT AXLE BEAM
Shape of the Billet - Round Corner Section
Size of Billet- 100mm Round Corner Section
Length of Billet- 1365mm
Weight of Billet - 106 Kg
Weight of Forging - 83 Kg
Weight of Flash & Gutter - 23 Kg
MATERIAL SPECIFICATION
Material used - 40Cr4 Type ‘C’
Composition of 40Cr 4 Type ‘C’
C – 0.40 to 0.45
Mn-0.70 to 1
Si - 0.10 to 0.35
S – 0.02 to 0.035
P – 0.035(Max).
Cr- 1.0 to 1.23.
BILLET HEATING
Billet is heated in the induction heater of size – 1365 mm billet length
100 mm RCS & heated at 1250°C.
Process Description
INDUCTION HEATER
Heating temperature – Zone (1) Temp - 4000C
Zone (2) Temp - 6000C
Zone (3) Temp - 8000C
Zone (4) Temp - 12500C
Function – Heating of Billet to proper Forging Temperature.
ROLLING
Function – Reduce the cross section of billet
MECHANICAL PRESS-Capacity – 2000 TON

Function – Produce the banding of billet (FRONT AXLE BEAM)

COUNTER BLOW HAMMER

Capacity-40 MTon (400Kj)
Function-Produce the Front Axle Beam with Flash & Gutter
TRIMMING PRESS
Capacity – 2100 TON
Function – Remove the flash and gutter form the forging.
COINING
Capacity- 2000 TON
Function- For flatning of PAD of Front Axle Beam.
HEAT TREATMENT
Hardening - Capacity – 4000 kg/hr (The Furnace is maintained at 8850C in case of Hardening)
Function – It provides the Hardness in the Job to give the better service life
Under loading conditions.
Furnace – BOFCO Hardening furnace
Temperature – 8800C Cycle Time – 3.5 hrs
Quenching Media – Polymer Quench Bath Temp. – 400C to 600C
Quenching – Quenching Time
Polymor Quenching-220 sec
Function – Quenched the heated Jobs & Maintain to 40 to 60°c temp.
Tempering - Capacity –4000 kg/hr
Function – After hardening the component is not used, it is used after tempering for better
service life under loading conditions.
Furnace – BOFCO Tempering furnace
Temperature – 5850C Cooling Media –Water
TENSILE STRENGTH
Capacity- 95 to 105 kgf/mm²
Function-10mm diameter in steel ball is use to measure the tensile strength.
SHOT BLASTING
Capacity – Total no. Of hanger 30 and (3 numbers of FA Beam per hanger)
Cycle Time - 4 min
Function – Remove the steel shot or scale form the Front Axle Beam.
FLASH GRINDING
This operation is done due to in the some forging the flash are extended in the someplace, it
creates problem in the machining operation. This operation is done be Grinding M/c to remove
the extended flash.
TESTING
This operation is done to check the defects in the forging mainly hair line cracks. For this
Magna-Flux Testing is done.
Manufacturing Steps of Front Axle Beam
CHARGING OR HEATING OF BILLET
The billet is charging in the induction heater, in the induction heater there are four zone which
are heating the billet in proper forging temperature.
ROLLING
When the billet is charge then it is go to the further stage that is rolling process. The heated billet
is transferring that machine by robotic system. This process the billet length is increase. There is
coolant agent water is used.
BENDING
When the billet is rolled by the rolling mill then the billet is bending by the Mechanical Press
which has 2000 Ton capacity.After the bending billet then it going on further stage of forging.
REHEATING
After the bending process the billet temperate is decrease which is not suitable for the forging
process so billet is heated up to the proper forging temperature. Then we go for the forging.
DE-SCALING & FORGING
The heated billet is free from scale by the de- scalar. And then it is Forging.
TRIMMING
forged by the Counter Blow Hammer, which has 2100 Ton capacity. After the forging process it
Produce the Front Axle Beam with Flash & Gutter.
After the forging process there is remains the flash and gutter which is removed by the Trimming
press to getting proper shape and size of front axle beam. The capacity of Trimming Press is
2100 Ton.

COINING
After trimming process we get the Front axle beam without flash & gutter and going on
further process that is coining process in this process we get the final shape of Front Axle Beam.
Which has 2000 Ton capacity .
After that we go to the further process.
HARDENING & TEMPERING
We got the final shape of Front Axle Beam then we doing Heat Treatment .In this
Hardening and Tempering process, which provides the hardness in the job to give the better
service life under loading conditions.
After the hardening the component is not used, it is used after tempering process.
PARTING LINE GRINDING
After the hardening and tempering process the component’s parting line grinding then it is going
on for the further process.
SHOT BLASTING
After the parting line grinding, component taken into the Shot Blast furnace for remove
the scale from the Front Axel Beam by using the small steel ball. After the shot blasting the
component are shining and free from scale.
SETTING & GRINDING
After shot blasting process the component are settled and grind. This operation is done
due to in the some forging the flash are extended in the someplace, it creates problem in the
machining operation. This operation is done be Grinding M/c to remove the extended flash.
CRACK TESTING
Crack testing is done after grinding process .This operation is done to check the
defects in the forging mainly hair line cracks. For this Magna-Flux Testing is done.
PAINTING
 After the crack testing, the painting process is done for the corrosion resistance and
resistance to any other element which is react with component material.
STORAGE & DISPATCH
At the end of all process the component is store and ready to dispatch.

FORGING DEFECTS
Cracks
Under filing
Overlap
Dent
Pitting
Tear
CRACK CAUSE AND REMEDY
Cause-1.Improper forging temp.
2.Forging at low temperature
3.Internal defects in raw material
4.Die chilling
Remedy-
1.Proper forging temp.
2.Forging at proper temperature
3.Defect less raw material
4.Preheating of die
UNDERFILLING CAUSE & REMADY
Cause-1.Improper forging temp.
2.Die chilling
3.Improper die design
4.Insufficient load
Remedy-1.Proper forging temp
2.Preheating of die
3.Proper die design
OVER LAP
Cause-1.Improper die design
2.Sharp corner radii
Remedy-
1.Proper die design
2.Fillet corner radii
DENT
Cause-1.Improper positioning of heated billet in die
2.Improper handling of job
3.Hot forgings are thrown from place to place
Remedy-
1.Proper positioning of heated in die
2.Proper handling of heated job
3.Hot forgings are kindly store one place to other place
PITTING
Cause-
1.Improper cleaning the die
2.Hot billets surface are not clean i.e presence of scale
Remedy-
1.Proper cleaning the die
2.Hot billet surface scale free
TEAR
Cause-
1.Low forging temperature
2.Poor quality of raw material
3.Burning of billet
Remedy-
1.Proper forging temp.
2.Good quality of raw material
3.Sufficient heating time
CORRECTIVE ACTION FOR DEFECTS

OFFSET
ICAS : - Segregation and grinding offset and recheck.
Root Case: - 1.Die mismatch.
2. Improper dove tail angle in die-holder.
3. Slide adjustment.
PCA Plan: - 1. Increase key ramming frequency.
2. Maintain dove tail angle.
3. Proper slide adjustment.
PAD UNDERFILL
ICAS : - Segregation by temple matchingand dimension checking.
Root Case: - 1. Improper rolling.
2. Wrong placement in die.
3. Improper coining.
PCA Plan: - 1. Ensure proper rolling length.
2. Proper placement in die.
3. Adjust packing during coining.
LENGTH OVERSIZE
ICAS : - 100% length checking by measuring table segregate grinding
Resetting and recheck.
Root Case: - 1. Improper soaking temp.and time.
2. Improper heat treatment.
3. Improper coining operation.
4. Improper setting and checking at fixture.
PCA Plan: - 1. Ensure proper forging temp. , soaking time and HT.
2.Ensure proper checking after setting.
PITTING
ICAS : - Visual checking for pitting, segregation, grinding and rechecking.
Root Case: - 1. Improper heating and soaking.
2. Improper die cleaning and descaling.
PCA Plan: - 1. Ensure proper heating and soaking.
2. Ensure proper die cleaning and descaling.
DENT
ICAS : - Segregate and check for dent material and grinding.
Root Case: - 1. Wrong die placement.
2. Trim die worn out.
PCA Plan: - 1. Ensure proper die placement.
2. Correction for worn and trim die.