A

SIX WEEK SUMMER TRAINING REPORT

On

GEARS

At

BHARAT GEARS LIMITED

Submitted for the partial fulfillment for the award of

Degree of
Bachelor of Technology
In
<Mechanical Engineering>

Maharshi Dayanand University , Rohtak

Session ( 2014-2015 )

Submitted By:-

JAI PRAKASH (12/ME032) ME-1 (3.1)

Under the Guidance of : submitted to:

Mr U.D bhatt (Production manager) Dr.R.sahai (head TPO)
And Mr. Rohit munjal (HR deptt) Mr. Gaurav kansal (head of ME deptt)

B.S. ANANGPURIA INSTITUTE OF TECHNOLOGY & MANAGEMENT, ALAMPUR,

FARIDABAD
 DECLARATION

I here by declare that the project work entitled “Industrial Training Report” Submitted to the Bharat
Gears Limited, is a record of an original work Done by me under he guidance of Mr. U.D. Bhatt sir &
Mr. Abhishek Yadav sir in Bharat Gears. It has not been altered or corrected as a result of assessment and
it may contain errors and omissions. The views expressed in it together with any Recommendations by
me.

Jai Prakash
 ACKNOWLEDGEMENT

I would like to express my sincere gratitude towards our educational institute B.S.A.I.T.M. who gave us
the opportunity to take training.
I would like to thank Mr. Rohit Munjal who allowed me to take the training at Bharat Gas Limited
Company.
I would also like to thank Mr. U.D. Bhatt under whose guidance I took training.
I would also like to express my gratitude towards Mr. Ajay without whose support I would not have been
able to aquire the knowledge.
Last but not least,I would like to thank all the workers for their co-operation.

Jai Prakash
 PREFACE

This is a report based on my experience at Bharat Gears Limited,Faridabad. Being a student of mechanical
engineering, I wished to gain exposure to the various aspects of working in an industry. This was a perfact
opportunity for me since the plant of Bharat Gears is one of the biggest production setups in India. My
primary goal was to gain some insight into methods of manufacturing and design, and during my time at the
shop-floor, I have achieved it to some extent. It was a good learning experience and will stand me in good
stand me in good stead in future

Jai Prakash
 TABLE OF CONTENTS

1.Introduction…………………………………………………………………… 1

1.1 milestones achieved

1.3 customers

1.4 products

2.analysis……………………………………………………………………… 13

2.1 gear terminologies

3.gear cutting processes………………………………………………………....19

3.1 inspect raw material

3.2 broaching

3.3 hobbing

3.4 shaping

3.5 rounding

3.6 shaving

3.7 punching

3.8 H.T

3.9 gear debburing

3.10 chemferring

3.11 Lapping

3.12 Grinding

3.13 Final inspection

3.14 Packing

4. Conclusion……………………………………………………………………34.

Referances
 INTRODUCTION 1

Bharat Gears Ltd. is one of the leading gear manufacturer in India. BGL supplies gears to major OEM’s in

India and overseas for different automobile industry like Heavy, Medium & light Trucks, Utility Vehicles

(UV’s), Tractors and Off highway vehicles

BGL’s strength encompasses world class quality, excellence in customer responsiveness right from

metallurgical quality control of basic steel to precision of gear cutting, HT and post HT operation along with

state of art machinery. It has diverse product lines with versatile applications.

It is a public limited Company. BGL is a majpr global supplier of automotive gears and heat treatment

furnaces.
 1.1 milestones Achieved 2

1972 Foundation Stone laid at Mumbra Factory by Chief Minister of Maharashtra. Mr. V.

P. Naik

1973 Production Commences at Mumbra Establishment

1980 First to have Gleason and Oerlikon System of Bevel gear generation under one

roof.
1981 - 2006 License agreement with AFC Holcraft, USA for furnace technology.
1985 - 2007 Technical and financial collaboration with ZF Friedrichshafen, Germany for

Transmission Technology.
1988  Awarded ISO – 9002 for Mumbra Plant.

 Start of Business with DANA Corporation, USA.

2000 Production begins at Faridabad Plant near Delhi.
2001 Mumbra and Faridabad Plants awarded QS – 900 certification by BVQI.
2004 Awarded ISO – 14001 to Faridabad Plant
2005 Awarded TS- 16949 certification to Mumbra and Faridabad Plants.

1.2 Plants 3

Plant Locations – Mumbra, near Mumbai

Faridabad, near Delhi

Plant Area Mumbra (sq.ft) Faridabad (sq.ft)

Covered 237,199 128,516
 Transmission Plant 34,096 15,970
Bevel Plant 51,700 19,852
Differential Plant 28,275 -
HT & IAF 25,275 25,275
General Office 83,801 10,396
Total 460,328 199,991

I) Bevel Unit

Manufacturing Overview:

 First to have both Gleason and Oerlikon system of Bevel Gear Generation in India.

 In house Gleason and Oerlikon tool Grindind facility.

 CDS and CAGE software for design and manufacturing capability.

 Cell Layout ( JIT) implementation.

 Oerlikon dry Cutting System (Closed loop) with KIMOS design/ manufacturing software by 2008.

Key Equipment:

 Gleason 608/609/610/611 CNC

 Oerlikon SM3/S17/S30 CNC/SKM1

 CNC Hobber

 GTR Chamfering Machine

 SL3 Lapping Machine / 507 CNC

 Nova CNC Bore Grinding Machine

 CNC Marking Machine 4

 Gleason Testers

 Spline rolling

 Shot Peening / Phosphating.

Product Range:

Gleason Oerlikon
Module (mm) 12.7 (outer) 8.5 (Normal)
OD (mm) 400 470
Quality AGMA 9 - 11
II) Transmission Unit

Key Equipment:

 Gleason TAG 400 – 8 Axis CNC Gear Grinding Machine

 Reishauer – RZ 301 AS CNC Gear Grinding Machine

 P 254 CNC Hobber / Leibherr L200 Hobber

 CNC Shaper CS 253/ Lorenz

 CNC External & Internal Grinding Machine

 Gas Metal Arc Welding Machine

 Swaging Machine

 Hurth SRS 402 shaving cutter sharpener

Product Range:

Gears Shafts
Module (mm) 5 mm 5 mm
OD (mm) 300 mm Dia 500 mm Length
Quality DIN 6-7 Grinding
DIN 8 Shaving

III) Differential Gear Unit

Key Equipment:

 Gleason Coniflex 104

 Gleason Revacycle 724 Twin Spindle

 Bore Grinder

 16T Vertical Broaching Machine 5

 Phosphating Setup

Revacycle Coniflex
Module (mm) 7.50 7.50
Pitch Dia(mm) 120 120
Quality AGMA 8 - 9

IV) Tool Room

This is used to manufacture the fixtures for various machines and under development parts.

V) Stores (Forging Yard)

 The forging received from the vendors are stored and checked for quantity and quality. A sample of

forging is subjected to metallurgical tests.

VI) Heat Treatment Unit

Key Equipment:

No of Furnaces :

 CGC – Continuous gas Carburizing – 4 No’s

 CQF – Continuous Quench Furnace with Cold oil / Hot oil Quenching Facility.

Sealed Quench Furnace – 6 No’s

 3 No’s H/C – SQF (500 Kg) – 2 No’s Tempering

 3 No’s GPC (General Purpose Carburizing)

 3 No’s Tempering Furnaces (SQF)(1 ton)

 Induction Softening, Induction Hardening (1 No’s)

 Endo. Gas generator ( 2 No’s)

 Shot Blasting / Hard Shot peeing.

VII) CNC Shop

Finish Turning of gear blanks and shafts is done. Products with precision dimensions are machined to pat

print specifications within accuracy of one micron by Turning, Drilling, Boring, undercutting, chamfering,

grooving etc. on machines like MORISEIKI, IMW, FENDT, TRAUB, MOFA etc.

VIII) IAF – Isothermal Annealing Furnace (2 No’s)

Iso – annealing and Normalizing is done in these furnaces for required parts. Tumb blasting is also done

here. There are hardness testers like Brinell Hardness Tester

QC is done in each shop after the respective treatments.

1.3 Customers
  Cararro Italy
 Dana Corporation, USA
 Eaton, USA
 JDCW, USA
 Motores John Deere, Mexico
 TDI, USA
 Transaxle Manufacturing of America (TMA), USA
 ZF, China
 Ashok Leyland
 Axles India
 Carorro, India
 Escorts
 Godrej
 Hero Motors
 Hyva India
 JDEPL – India
 JCB – India
 Mahindra and Mahindra
 New Holland Tractors ( India)
 Paharpur Cooling Towers
 Same Deutz – Fahr
 Spicer India
 Swaraj Mazda
 Tafe
 Tata Motors
 Toyota Kirloskar Auto Parts
 Voltas 7
 VST Tillers & Tractors
 BRP International

FURNACE – DIVISION
 Ashok Leyland
 Automotive Axles ( Part of Arnin Meritor)
 Bajaj Auto
 Ceekay Daikin
  FairField Engineering
 Varroc Engineering
 Hindustan Motors
 Mahindra and Mahindra
 Precision Fasteners
 Sona Koyo Steering Systems
 Tata Motors
 Timkin India
 Tractors Engineers (L & T)

1.4 Products

Ring Gear and Pinion :

BGL manufactures a variety of Ring gears and Pinion set to service a variety of trucks, buses cars

and utility vehicles. It offers both world famous systems of hypoid gear generation – Gleason ( Face

Milling) and Oerlikon ( Face Hobbing).

Transmission Gears and Shafts :

BGL facility includes state-of-art machines like Gear shaping, hobbing, shaving and gear grinding

machines as well as gear testers & induction hardening machines. BGL’s latest acquisition in gear grinding

has been the Gleason Tag 400 cylindrical Gear Grinder. The

machine has 8 axes on CNC and is highly productive. All

possibilities of profile / lead modifications can be obtained.

BGL’s gears conform to DIN 6 to DIN 8 class accuracy.

Differential Gears (Satellite, Planetary and Spider Gears) BGL offers to their customers a choice of

two systems – Gleason Coniflex and Gleason Revacycle systems of Straight bevel Generation.

In addition to these BGL manufactures Differential Crosses (Trunnions) of various sizes as well as complete

sub-assemblies of differentials.
A Particular Gear Box assembly is as follows :

10

Furnaces

BGL’s

Furnace
Division Engineers constructs batch and continuous heat treating furnace systems in collaboration with AFC

– Holcraft Michigan, USA.

Systems 11

 Quality Systems

 ISO 9001 – 2000 Certification

 ISO 16949 – 2000 Certification

 Management Information System

 Local Area Network of computers at plant and Head Office

 Unit wise cost analysis and control

 Human R D – System

TQM Culture through

 Total Customer Satisfaction

 Total Employee Involvement

 Total Waste Elimination

 Total Quality Management :

To keep pace with time in this liberated economy to enhanced national and international
growth, to create quality and to maintain marketing leadership. TQM is where positive thinking is
core element.

TQM Thrust Areas are :

 Management Responsibilities
 Delegation and Decentralization
 Total Customer Delight
 Strategic quality planning
 Human resource utilization
 Product quality assurance
 Company wide computerization
 Implementation of ISO / TS 16949 – 2000
 Reduction in waste and cost
Some of the outputs from these thrust areas gives some organization values, which are:::
 Technology
 Quality Assurance
 Higher Performance
  Passiveness Objectives
12
TQM gives more emphasis on management as change of management gives more change in one
serieschanges in culture and change in one’s thought process.

Bharat Gears Quality Policy

 We are committed to provide products that meet mutually agreed requirements of our customer and

to ensure their full satisfaction.

 We undertake to continually improve our processes and quality systems.

Quality Objectives:

 To reduce rejection (ppm).

 To reduce operation cost.

 To increase productivity.

 To reduce new product development cycle time.

 To ensure online delivery.

Departments

Quality Control :

The Quality control department sees that parts manufactured confirm to requirements. This

department performs forging inspection, in process inspection before heat treatment inspection, After heat

treatment inspection and final inspection.

Maintenance Department :

It includes mechanical maintenance as well as electrical maintenance. The preventive breakdown

maintenance is carried out in BGL.

Purchase Department :

Deals with inventory tendering and vendoring, stock purchase and need verification bills, payments,

insurance, etc…
 Marketing Department :

13

Marketing Dept. looks after the flow of orders, maintaining good relations with customers, taking payments

from the customers after fulfilling their orders. Marketing department also do advertisement for the

company.

BU & TU Engineering Department:

Department:

Function – Developing the parts, Preparing part and / or assembly drawings, estimating the tooling

and gauging cost and raising the indent for the same to initiate PO, preparing Control Plan, Process sheets,

Process flow diagrams, developing fixtures for various machining processes, helping the production dept. in

quality and Technical Problems.

Industrial Engineering Department :

Functions :

 Time Study and Estimation for machine line, stores, and tool room and assembly

operations.

 Layout modification and designing new layouts of production line, stores and offices.

 Designing and providing material handling and storage facility for machine line,

assembly line and stores.

2. ANALYSIS

2.1 GEAR TERMINOLOGIES Gears

Position of axes of Relative motion Forms of teeth

shafts

low medium high

Involute Cycloidal

Intersecting axes ( Non – Intersecting

Parallel axes Bevel Gears) axes( Worm and
( Spur and Worm Wheel)
Helical)
 14

Gears having Parallel axes :

These gears have teeth parallel to the axis of the wheel . These consist of Spur and Helical type of

gears. Spur Gears are those in which the teeth are parallel to the axis and helical type in which the teeth are

inclined to the axis.

Gears having Intersecting axes :

The two- non parallel or intersecting, but coplanar shafts connected by gears are called bevel gears

and the arrangement is known as bevel gearing. The bevel gears, like spur gears may also have their teeth

incline to the face of the bevel, in which case they are known as helical bevel gears.

Non-intersecting and Non-Parallel axes :

Two non – coplanar shafts connected by gears is known as skew bevel gears or spiral gears and the

arrangement is known as skew bevel gearing or spiral gearing. This type of gearing also have line contact,

the rotation of which about the axes generates the two pitch surfaces known as hyperboloids.

Terms used in Gears :

I) Spur Gears :

  Pitch Circle : It is a imaginary

circle which by pure rolling action, would give the same motion as the actual gear.
15
 Pitch Circle Diameter : It is the diameter of the pitch circle. The size of the gear is usually specified by
the pitch circle diameter. It is also called as pitch diameter.
 Pitch Point : It is a common point of contact between two pitch circles.
 Pitch Surface : It is the surface of the rolling discs which the meshing gears have replaced at the pitch
circle.
 Pressure angle or angle or obliquity : It is the angle between the common normal to two gear teeth at
the point of contact and the common tangent at the pitch point. It is usually denoted by ф. The standard
pressure angles are 14 1/2o. and 20o.
 Addendum : It is the radial distance of a tooth from the pitch circle to the top of the tooth.
 Dedendum : It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
 Addendum Circle : It is the circle drawn through the top of the teeth and is concentric with the pitch
circle.

 Dedendum Circle : It is the circle drawn through the bottom of the teeth. It is also called root circle.

 Circular Pitch : It is the distance measured on the circumference of the pitch circle from a point of one
tooth to the corresponding point of the next tooth. It is usually denoted by pc.

 Diametrical Pitch : It is the ratio of number of teeth to the pitch circle diameter in millimeters. It is
denoted by pd.

 Module : It is the ratio of the pitch circle diameter in millimeters to the number of teeth. It is usually
denoted by m.

 Clearance : It is the radial distance from the top of the tooth to the bottom of the tooth, in a meshing
gear. A circle passing through the top of the meshing gear is known as clearance.

 Total Depth : It is the radial distance between the addendum and dedendum circle of a gear. It is equal
to the sum of addendum and dedendum.

 Working Depth : It is the radial distance from the addendum circle to the clearance circle. It is equal to
the sum of addendum of the two meshing gears.

 Tooth Thickness : It is the width of the tooth measured along the pitch circle.

 Tooth Space : It is the width of space between the two adjacent teeth measured along the pitch circle.
16
 Backlash : It is the difference between the tooth space and the tooth thickness, as measured on the pitch
circle.

 Face of the tooth : It is the surface of the tooth above the pitch surface.

 Top land : It is the surface if the top of the tooth.

 Flank of the tooth : It is the surface of the tooth below the pitch surface.

 Face width : It is the width of the gear tooth measured parallel to its axis.

 Profile : It is the curve formed by the face and flank of the tooth.

 Fillet Radius : It is the radius that connects the root circle to the profile of the tooth.

 Path of contact : It is the path traced by the point of contact of two teeth from the beginning to the end
of engagement.

 Arc of contact : It is the path traced by a point on the pitch circle from the beginning to the end of
engagement of a given pair of teeth. The arc of contact consists of two parts, i.e.

17
18
 a) Arc of recess : It is the portion of the path of contact from the pitch point to the end of the
engagement of a pair.
 Pitch Cone : It is the cone containing the pitch elements of the teeth.
 Cone Centre : It is the apex of the pitch cone. It may be defined as that point where the
axes of the mating gears intersect each other.

b) Arc of approach : It is the portion of the path of contact from the beginning of the
engagement to the pitch point Arc of recess : It is the portion of the path of contact from the
pitch point to the end of the engagement of a pair.
 Pitch Cone : It is the cone containing the pitch elements of the teeth.
 Cone Centre : It is the apex of the pitch cone. It may be defined as that point where the
axes of the mating gears intersect each other.
c)
d) Arc of recess : It is the portion of the path of contact from the pitch point to the end of the
engagement of a pair.
 Pitch Cone :point
:point where the axes of the mating gears intersect each other.
 Pitch angle : It is the angle made by the pitch line with the axis of the shaft. It is denoted
by θP.
 Cone distance : It is the length of the pitch cone element. It is also called as pitch cone
radius.
 Addendum angle : It is the angle subtended by the addendum of the tooth at the cone
centre, It is denoted by α.
 Dedendum angle : It is the angle subtende by the dedendum of the tooth at the cone centre.
It is denoted by β.
 Face angle : It is the angle subtended by the face of the tooth at the cone centre. It is
denoted by Ф. The face angle is equal to the pitch angle plus the addendum angle.
 Root angle : It is the angle subtended by the root of the tooth at the cone centre. It is
denoted by θR. It is equal to the pitch angle minus dedendum angle.
 Back (or
(or normal ) cone : It is an imaginary cone, perpendicular to the pitch cone at the end
of the tooth.
 Back cone distance : It is the length of the back cone. It is denoted by RB. It is also called
back cone radius.
 Backing : It is the distance of the pitch point (P) from the back of the boss, parallel to the
pitch point of the gear. It is denoted by B.
19
  Crown height : It is the distance of the crown point C from the cone centre (O). parallel to
the axis of the gear. It is denoted by HC.
 Mounting height : It is the distance of the boss from the cone centre. It is denoted by HM.
 Pitch Diameter : It is the diameter of the largest pitch circle.
 Outside or addendum cone diameter : It is the maximum diameter of the teeth of the gear.
It is the diameter of the blank from which the gear can be cut.
 Inside or dedendum cone diameter : It is the inside diameter and is denoted by Dd.

3. GEAR CUTTING PROCESSES

For Systematic Processing of Gears from forging operation till grinding, shaving or inspection (QC). A PFD
(Process Flow Diagram) is prepared. All the processes on the corresponding gear, crown wheel, pinion or
differential gears is carried out according to the instructions in the process flow diagram. A typical PFD is as
attached.
For every Process a Control Plan (CP) is prepared. The instructions given in the CP are very
essential and the operator works on the corresponding to the CP.
A typical CP is as attached:

Some of the gear processing terms as in PFD are as follows:

3.1 Inspect Raw Material: The raw material used for making a gear is inspected for necessary
metallurgical considerations.The raw material should be crack and dent free.This inspection is done
visually as well as by machine.

Inspect Forging: The Forging of the required parts(gears) which comes from the vendors is
inspected at this stage.

Finish Turning: Turning on the part is done using CNC turning machines in the
CNC(Computerized Numerical Control) shop located inside the factory. Majority of the parts are
given to the vendor for finished turning which are then inspected in the factory.

20
3.2 Broaching: Broaching is done using the Arthur Klink Broaching machine located in the
transmission shop. Broaching is a method of removing metal by pushing or pulling a cutting tool
called a broach which cuts in fixed path.
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 work piece to affect 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 work piece to cut an axis symmetric 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.

• Broaching Cutter :
SPLINES:
1.Straightn
2. Involute 21
 3. Serrations
4. Trapezoidal
INTERNAL HOLE:
1. Square
2. Round
3. Rectangular, Hexagonal
4. Irregular Shapes etc.
KEYWAY:
1. With or without Chamfer
2. Convex/Concave.
3. Combined Round & Single Keyway
• Product Parameter :
1. Major Dia. : Paddle Gauge
2. Minor Dia. : Plug Gauge
3. Face R/O & O.D R/O : Bench Center With Dial Stand
4. Finishing Spline : Visually

3.3 Hobbing:

Hobbing is a machining process for gear cutting,cutting splines. The teeth or splines are cut into the
workpiece by a series of cuts.These cuts are made by a cutting tool called hob.It is the most widely used gear
cutting process for creating spline and making gears.
Hobbing uses a hobbing machine with two skew spindles,one mounted with a blank workpiece and other
with a hob. The angle between hob’s spindle & workpiece’s spindle varies,depending upon the the type of
gear that we have to produce. If spur gear is being produced,the hob is angled equal to the helix angle of the
hob.The shafts are rotated at a proportional ratio which determines the number of teeth on blank.
e.g; If gear ratio is 40:1,the hob rotates 40 times to each turn of blank which produces 40 teeth in blank.
Hob is fed up into workpiece until correct tooth depth is obtained. Finally hob is fed up through workpiece
parallel to blank’s axis of rotation.

Hob:

The hob is the cutter used to cut the teeth into the work
piece. It is cylindrical in shape with helical cutting teeth.
These teeth have grooves that run the length of the hob,
which aid in cutting and chip removal. There are also
special hobs designed for special gears such as the spline
and sprocket gears
.
Process Parameter :
1. Hob Cutter O.D Run Out On Machine : 0.010 mm
2. Locator O.D Run Out : 0.010 mm
3. Locator Face Run Out : 0.010 mm
4. Top Center Run Out With Respect To Workable : 0.010 mm

Product Parameter :
1. D.O.P : Micrometer
2. R.O.P : Bench Center With Dial Stand
3. T.C.E : Gear Roll Tester
4. T.T.C.E : Gear Roll Tester
5. Helix Error : Lead Profile Tester
6. Lead Variation : Lead Profile Tester
7. Profile Error : Lead Profile Tester
8. Profile Variation : Lead Profile Tester
9. Root Dia. : Vernier Caliper
10. Semi Topping : Vernier Caliper
3.4 Shaping: 23

Shaping is also a process of cutting teeth using a cutter. Shaping is done at that place of gear where the
hobbing is not possible. The cutter in shaping machine is a disc cutter which reciprocates as well as rotates
in axial direction. The blank gear rotates on second spindle. The workpiece is aligned with cutter and slowly
feeds into cutter while rotating. It is generally used for cutting dog teeth on gears.

SHB Manufacture Gear Shaping Cutters in Module, DP and CP series. Spur as well as
Helical Shaper Cutters can be supplied in Disc, Hub and Shank Type Varieties. Material used is
generally AISI M35 Grade and accuracies are as per DIN-1829 Standard Class ‘AA’ and Class ‘A’. Profile
modifications including Chamfer, Semi-Topping, Topping , Protuberance, Flat or Fillet Root can be
provided.

Process Parameter :
1. Cutter O.D Run Out On Machine : 0.010 mm
2. Cutter Rake Face Run Out : 0.010 mm
3. Locator O.D Run Out : 0.010 mm
4. Locator Face Run Out : 0.010 mm

• Product Parameter :
1. D.O.P : Micrometer
2. R.O.P : Bench Center With Dial Stand
3. Helix Error : Helix Tester
4. Root Dia. : Vernier Caliper
5. Semi Topping : Vernier Caliper
6. Free Entry Of Matting Part : Go gauge
7. Teeth Finish : Visually
8. Spline Rotation Must Be Not Enter : No Go gauge

3.5 Rounding:

Rounding is the process of making the edges of the teeth in round shape for better meshing of gears. When
the gear has to slide into mesh,the edges of teeth,on sliding member & the corresponding edges of teeth on
 24
the mating member are rounded to ease meshing. The cost of rounding tool is more therefore chamfering can
also be done.

3.6 Shaving:

Gear shaving process improves the surface of gear flanks. It also reduces tooth profile error,index error &
lead error on gears manufactured by hobbing & shaping process.
The process of shaving involves running the shaving cutter in tight mesh with the work gears at high speed
or gear shaving machine. During rotation,cutting edges sweep over flanks and remove the fine hair like
chips.
 Advantages of Shaving::

i. Improvement of surface finish.

ii. Gear noise is reduced.
iii. Transmitting high power at high speed.
iv. Life of gear is enhanced.

Shaving Cutters :
Transverse Shaving Cutters :

The gear that is shaved reciprocates in the direction of its own axis. The tool and the gear are in mesh. With
each steps of reciprocation, there is an occurrence of small quantity of radial feeding of the
shaving cutter.

Diagonal Shaving Cutters :

26
Here the gear selected for shaving reciprocates obliquely in direction to its own axis. The gear and the tool
are made to stay in a mesh. The diagonal angle can be got by positioning of the work piece table in an
oblique manner or by the process of interpolating of the two machine axes. As with each reciprocation, there
is a radial feeding of the shaving cutter. This is described in the diagr

Plunge Shaving Cutters :

In this method there is no worktable translation. Instead there takes place a radial feed of the work piece
against the tool that is used as shaving cutter. Plunge shaving is particularly good for shaving of shoulder
gear

Underpass Shaving Cutters :

Underpass shaving is primarily identical to diagonal shaving with a small variation in the form of a diagonal
angle of 90 degrees. In underpass shaving no axial table reciprocation takes place. In its place, the work
piece reciprocates at right angles to its own axis.

3.7 Punching:

Punching is the process of making customber number on the gear. This number contains the name of the
furnace used,year-month & the number required by the company which purchases the gears . Punching is
done by manually as well as computerized. The information is fed into the computer and punching machine
makes the customber number.

B.H.T. Inspection:
B.H.T. means before heat treatment inspection. It includes visual inspection of gears like
teeth,finishing,chamfering is okey or not,no dent available on gear & chips must not stick on the gear.

3.8 H.T.:
Heat treatment is the process of improving physical,chemical,metallurgical properties. The surface hardness
which imparts wear resistance to prevent tooth & bearing surfaces from wearing . It also improves gears
fatigue life. Physical properties like surface hardness,core hardness,ductility,strength,compressive stress
can vary depending upon the type of heat treatment. Two types of furnaces are used for H.T. :-
 CGC furnace
 GPC furnace

CGC furnace:

CGC means continuous gas carburising furnace that is a multichamber furnace. It uses propane gas 100
kg /hr.
Quenching oil is Houghton Hi-quench coil oil. It is used for H.T. of larger parts.

GPC furnace:

GPC stands for General Purpose chamber Furnace.

It is also a multichamber furnace used for H.T. of smaller parts as compared to CGC furnace. Oil required in
this furnace is 7000 Lt / GPC.
Four gases are used in GPC furnace:- Propane,Endo,NH3(Ammonia) and Air.

Shot Blasting

• Process :
Shot Blasting is the process after Heat treatment in which remove the product
darkness which occurs in heat treatment process . In this Process 52 to 60 HRC
hardness stainless steel small particles strike on product

3.9 Gear Deburring:

Gear deburring machines are designed to correctly remove burrs or sharp edges as a
result of castings, drilled holes, cut grooves and other machining operations used to
complete parts. The Deburring process of gears makes the parts capable of a
performance for which they were designed. It eliminates all the unwanted elements
that obstruct their productivity.

Deburring cutter:

29
SHB manufacture Gear Deburring Cutters to remove burrs formed during teeth cutting and chamfering
operation. These cutters are used in conjunction with Gear Chamfering Cutters. Material used is mainly HSS
M-2. Gear Deburring Cutters for Samputernsilli Machines ca be manufactured in standard form as well as to
the specific requirements of the customer.

3.10 Chamfering

• Process :

Chamfer is a beveled edge connecting two surfaces. If the surfaces are at right angles, the
chamfer will typically be symmetrical at 45 degrees. A fillet is the rounding off of an interior corner.

3.11Lapping

• Process :
Lapping is a machining operation, in which two surfaces are rubbed together with an
abrasive between them, by hand movement or by way of a machine. This can take two
forms. The first type of lapping (traditionally called grinding), typically involves
rubbing a brittle material such as glass against a surface such as iron or glass itself
(also known as the "lap" or grinding tool) with an abrasive such as aluminum oxide,
jeweler’s rouge, optician's rouge, emery, silicon carbide, diamond, etc., in between
them. This produces microscopic conchoidal fractures as the abrasive rolls about
between the two surfaces and removes material from both.
 Quenching:
It is the rapid cooling of workpiece to obtain certain material properties. It increases the surface hardness of
workpiece, After H.T. the gear comes into the highly quenched oil for quenching.
quenching

A.H.T. Inspection:
30
A.H.T. refers to After Heat Treatment Inspection of gears.It includes the inspection of gears by means of
instruments:- micrometer,height gauge,pitch circle diameter, Outer Diameter,InnerDiameter. Sometimes gear
shaft slightly bend and then it is straightened by straightening machine.

3.12 Grinding:
Grinding is a finishing operation. Accuracy of the various dimensions is achieved in the tolerance range of
very few microns. Several type of Grinding processes are carried out like face grinding, profile grinding,
thread grinding etc

.
Process :

Grinding machine consists of a power driven grinding wheel spinning at the required speed (which is
determined by the wheel’s diameter and manufacturer’s rating, usually by a formula) and a bed with a
fixture to guide and hold the workpiece. The grinding head can be controlled to travel across a fixed work
piece or the work piece can be moved whilst the grind head stays in a fixed position. Very
fine control of the grinding head or table’s position is possible using a vernier calibrated hand wheel, or
using the features of numerical controls. Grinding machines remove material from the work piece by
abrasion, which can generate substantial amounts of heat; they therefore incorporate a coolant to cool the
work piece so that it does not overheat and go outside its tolerance. The coolant also
benefits the machinist as the heat generated may cause burns in some cases.

Diamond tool :
A diamond tool is a cutting tool with diamond grains fixed on the functional parts of
the tool via a bonding material or another method.
25
• Advantages of diamond grinding tools :
1. High grinding efficiency, Low grinding force
2. High wear resistance.
3. Long lifespan, Long dressing period:.
4. Low comprehensive cost

Induction Hardening Process

• Process :

1. Completion of all machining operations.

2. Pre heat inspection and punching.
3. Stress relieving (at 250c, 2 Hr.)
4. Oiling
5. Job resting faces cleaning by polishing paper.
6. Induction hardening (Internal/External)
7. Oiling
8. Tempering must be within 4 hr. 32
9. Oiling

• Advantages :
1. Induction Hardening is very use full to increasing the hardness of product either internally or externally.
2.It is use to make brittle material of product

Kerosene Cleaning:
The gear is cleaned using kerosene.It is final process of gear manufacturing in which thegear is washed in
oil, so that gears can be prevented from corrosion. The oil is filled in thechamber & the gears are washed
into it.

3.13 Final Inspection:

Final Inspection of the part is done in the Final Quality Control Department.

3.14 Packing:
Packing is done in F.G.S. after which the gear is dispatched to the customer.

Some Other Operations done on various parts are:

Drilling: Drilling of holes of various sizes and lengths is done using CNC drill. Gun drill is used for long
hole drilling.
Grinding: Grinding of the bore in case of crown wheel is done using bore grinding machines.
Phosphating: Phosphating is done to improve surface characteristics of the part. It is done in the
following steps:
1) Precleaning
2) Degreasing (Protoklin -301(D) 70o + 5o.
3) Cold Water Tank
4) Hot Water Tank
5) Phosphating Tank
6) Cold Water Tank
7) Oil Tank.

Common Packing

NEED
 Packing is the most important part after Gear finishing operations are completed because damage of

the part may occur while transportation, which can lead to teeth damage. Packing is to be done in such a way

that maximum no. of parts can be used for the same box drawings known as common packing which

reduces the design cost of newer boxes. Also fewer no. of boxes are easy to handle which makes it pretty

easier. Also sometimes more than one part can fit into the boxes of dimensions designed saving materials.

Considering the Outer Diameter, Inner Diameter, type of gear, Shape, Engg. Drawing, length (or

height) etc. box drawings are made. So if all these considerations lie within tolerances of +15 mm or as

mentioned.

The movement of parts while transportation should be minimum so that there is no damage to the

parts. For packing presently, for the three units i.e. Transmission, Bevel and Straight Bevel, the pattern of

boxes used is as follows:

Transmission:

 Corrugated box – primary pkg.

 Plastic Crate - <Returnable> For near by customers

 Plywood box – Export (Secondary pkg)

 Wooden – Domestic

 Bevel

 Plastic Crate

 Clip-lok box

 Wooden box

 Plywood box

Straight Bevel

 Corrugated box

 Plastic Crate

 Wooden box

 Plywood bevel

34
4 CONCLUSION :

After completing the industrial training at ‘BHARAT GEARS PVT. LTD.’ I can say that the industrial

training is very important for Engineering students like me. Practical knowledge is a very important in the

every field. It was great experience during the industrial training and I learnt practically knowledge about

the different machines like Hobbing, Shapping, Shaving etc. uses to cut the various gear like spur, helical,

spline,etc. Various processes such as turning, milling, grinding, keyway and shaping of gears teaches me a

lot of things. I also took some experience about the organization’s work. The employees of the company

were supportive during the industrial training. Employees and Ajay sir under whose guidance i took training

help me to understand the mechanisms and theories behind these various processes. They provide me the

proper guidance and information about all the departments like marketing, production and personnel, etc.
REFERENCES :

WWW.BHARATGEARS.COM

 The company

 Product

 Infrastructure

 Qualities

WWW.GOOGLE.COM

 Google Images

 Gear Cutter

WWW.WIKIPEDIA.COM

• http://En.Wikipedia.Org/Wiki/Bevel

 http://En.Wikipedia.Org/Wiki/Numerical_Control

 http://En.Wikipedia.Org/Wiki/pinion

WWW.DIFFERENCIALGEARS.COM

 Bevel gears
 pinions