Gajra gear ppt

GEAR
By:-priyanshu kumar

1. MEDI-CAPS INSTITUTE OF TECHNOLOGY & MANAGEMENT Presentation on Industrial Training At Gajra Differential Gears Ltd. Dewas Submitted to: Mr. Jayesh Barve Mechanical Department MITM, Indore Submitted by: Nitesh Kumar

2. Company Profile Gajra Differential Gears was formed in 1991 to cater to the ever-growing needs of the axle gear market for cars, trucks, and tractors. Currently  Gajra Gears is the largest manufacturer of automobile transmission gears in India. Comprise of 130,000 sq. ft. machine shop area and a 29,000 sq. ft. heat treatment facility. It has a strength of over 1000 trained and committed employees and offering a range of around 1700 gears for virtually every major brand of truck, car, jeep, and tractor. ISO-9000, Better Manufacturing Practices. Best Manufacturing Practices - Six Sigma, TPM, TQM.

3. Products Spiral and Hypoid Gears (Crown Wheel and Pinions) Module: 2.5 to 12 module Outside Diameter: 100mm to 500m Bevel Gears Module: 1.5 to 10 module Outside Diameter: 30mm to 300m Spider Kit Assemblies Differential Cages and Housings

4. Export of Products More than 50% of the products manufactured at Gajra Gears are exported across the globe. Precision-cut gears are exported to USA, Germany, Nigeria, Malaysia, Thailand, UAE, Iran, Sri Lanka, Canada, Australia and China. The group's wide export range includes replacement gears for Mercedes, Bedford, Hino, Fuso, Isuzu, Daihatsu, Mitsubishi, Magirus Deutz , Nissan, Toyota,  Willy's, Peykan , Tung Feng , Volvo, Eaton, Clark, Fuller, New Process, Dana, Ford, ZF, Getrag , Massey Ferguson, International Harvester and various others.

5. Flow Chart showing Gear Manufacturing Processes Packing Inspection of Forging and Blanks Facing & Centering CNC Turning Drilling, Reaming, Tapping Keyway spline milling or Hobbing Teeth Cutting Heat Treatment Grinding Final Inspection After Heat Treatment Inspection Pre Heat Treatment Inspection

6. What is a Differential Differential is a mechanical device made up of several gears including crown wheel & tail pinion and Kit (Kit comprises of Bevel gear, Bevel pinion gear and Spider gear). It is used to transmit power from drive shaft to drive wheels and allows wheels on the same axle to rotate at different speeds.

7. At straight Road At Turns

8. Differential Assembly Crown Wheel Tail Pinion Kit 2 Bevel gear 4 Bevel pinion Spider gear

9. Inspection of Forging & Blanks Forging inspection procedure: Dimensional checking Chemical analysis Metallurgical testing Machined blank inspection Crown wheel Tail pinion Bevel gear Bevel pinion Spider

10. Pre Teeth Cutting Operations Facing and Centering Drilling, Reaming & Tapping Keyways Splines Hobbing Broaching Milling

11. Cutting Tools According to tool strength HSS Steel or Carbide tip (Shiny silver color ) Tin Coated (Gold color )

12. According to blade insertion Ring type Inserted type

13. Teeth Cutting Section Crown Wheel 2 Cut cycle Roughing (GL-608 R) Finishing (GL-609 F) Tail pinion 3 Cut cycle Roughing(GL-116 R) Concave finishing (GL-118 outer blade) Convex finishing (GL-118 inner blade) Kit (Bevel, Bevel pinion, Spider) Single cut cycle (GL-104, GL-114)

14. Pre Heat Treatment Inspection Inspection of Dimensions as per drawing (Vernier & Dial guage ) Bore diameter Threads (Plug guage ) Splines (Full form guage ) Surface finish Tolerances (Dial guage ) Outness Correctness of crown wheel & tail pinion.

15. Heat Treatment Pre-washing Pre-heating Carburising (Temp. 890-930⁰C) Headening (Temp. 820-860⁰C) Quenching (Oil quenching) Post washing Tempering (Temp. 40-200⁰C)

16. Mr. K.K. Sinha explaining us the working inside The Heat Treatment Plant

17. After Heat Treatment Processes 1. Hydraulic Pressing

18. 2. Short Blasting & Peening

19. 3. Phosphating

20. After Heat Treatment Inspection Hardness test done on: Crown Wheel Tail Pinion Spider Bevel gears Study of grain structure Checking of dimensions and tolerances of the different gears

21. Gear Finishing Shaving a cutter having the exact shape of the finished gear tooth Only small amounts of material are removed by a rolling and reciprocating action Grinding Honning Honing polishes the gear tooth surface and can be used to correct minor errors in gear tooth geometry Lapping Done by preparing a paste of Honila oil and silica

22. Grinding Section Grinding is done on following machines: Jonship Main Cylinder Grinder Russian Spline Grinder Cylinder Grinder Landis Grinder

23. Final Inspection After Lapping Operation inspection of final Crown-Wheel-Pinion on Testing Machine. Assembly of Kit assembly Final rolling of Differential housing

24. Packing of Gears Packing of following in boxes: C.W.P. Set Spider Kit assembly Housing Marking of crates for Export shipment Precautions during packing to avoid Rusting of gear set Dents & damage to gear Mis -matching of C.W.P. set

25. Packing of Gears

26. Thank You