INDUSTRIAL TRAINING AT Mahindra Gears & Transmissions Pvt. Ltd. Shapar Road, Rajkot (Gujarat) Prepared By: Faldu Krunal B. Tech 4th Year (7th Semester) Mechanical Engineering J.N.U. JODHPUR R.No: 08ET405079

INTRODUCTION Mahindra gears is one of the leading manufacturing of proven quality gears and other transmission component in India since 1987. The facility comprises of 3 work shops of sizes 800 sq. mts, 1000 sq. mts, 4000 sq. mts. With a complete stand by power for the entire premises.

SERVICES & MAJOR FUNTION Mahindra Gears & Transmissions Pvt. Ltd. Produce more than 2,50,000 quality assured gears a month, conforming to German specification DIN 7 to DIN 9 class of accuracy. They are certified to TS 16949 quality system requirements, from TUV. Mahindra Gears manufactures auto components comprising of automobile gears like Spur, Helical, Straight Bevel, Sprockets along with Transmission Saline Shaft, Couplings and Power Takeoff Clutches which are used for Transmission, Engine and Differential gear boxes.

VARIOUS DEPARTMENT /SHOP New Production Development Department Vendor Supplied Area / Raw material Storage SCM department Primary Inspection Department Maintenance Department Production Shop Heat Treatment shop Shot Blasting Shop Grinding Shop Eaton Hub Cell Pre Dispatch Inspection Department Final Inspection (Domestic/Export)

CUSTOMER International Tractor Ltd. Tata Motors Ltd. DANA India Ltd. Eaton Hub Pvt. Ltd.

VENDORS Forging Machining Heat Treatment Kadvani Forge Ltd. Niku Forging Pvt. Ltd. Hindustan Motors Pvt. Ltd. Machining Jyoti CNC Automation Turn well Industries Krishna Engineers Heat Treatment Ravi Metal Treatment Inducto Hardening Advance Mechanical Works

MANUFACTURING PROCESS HOBBING:-

PROCESS Hobbing is a machining process for making gears & splines. which is a special type of milling machine. The teeth or splines are progressively cut into the work piece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and in expensive.

SHAPPING:-

PROCESS A gear shaper is a machine tool for cutting the teeth of internal or external gears. The name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away from the part on the return stroke, just like the clapper box on a planer shaper. The cutting tool is also gear shaped having the same pitch as the gear to be cut.

BROACHING:-

PROCESS Broaching is a machining process that uses a toothed tool called a broach to remove material. This are two mainly type of broaching (Horizontal & Vertical). It is the most common used process to cut internal gear quick and more accurate. Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include circular & noncircular holes, splines, key-ways and flat surface.

SHAVING:-

PROCESS Gear shaving is basically a finishing operation. This takes place after the operations of roughing with a hob or cutting with a shaper cutter is over. The Shaving process consists of the removal of tiny particles of metal from a gear teeth's working surface. Gear shaving produces fine hair like chips. The cutter comes in the form of helical gear. It has special serrations in the flank area of gear teeth. These “serrations” act as the cutting edges.

ADVANTAGES Improves tooth surface finish. Effective reduction in the noise of gears with modification in the tooth profile. Increase the gear’s load capacity Improved safety and service life.

SHOT BLASTING:- 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 stainless steel particles strike on product.

DEBBURING:- 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.

ROUNDING:- Rounding is a process in which the tooth sharp corner is cut by the rounding cutter. A rounding cutter is an exterior corner is called a "round" or a "radius”.

LAPPING:- Lapping is a machining operation, in which two surfaces are rubbed together with an abrasive. The one type of lapping (called grinding), typically involves rubbing a brittle material such as aluminum oxide, 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.

GRINDING MACHINE:-

PROCESS Grinding machine consists of a power driven grinding wheel spinning at the required speed. The grinding head can be controlled to travel across a fixed work piece or the work piece can be moved while the grinding 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.

Turning machine:- Turning is the process where by a single point cutting tool is parallel to the surface. It can be done manually, in a traditional form of lathe, which frequently requires continuous supervision by the operator, or by using a computer controlled and automated lathe.

Hard turning Soft turning Hard turning is a turning done on materials with a Rockwell C hardness is greater than 45. It is typically performed after the work piece is heat treated.   Soft turning Soft Turning is turning done to soft materials which are without heat treatment process and its hardness is lower than Rockwell C hardness 45.

HEAT TREATMENT PROCESS:-

PROCESS Heat treatment process is a series of operations involving the heating and cooling of metals in the solid state.  Its purpose is to change a mechanical property or combination of mechanical properties so that the metal will be more useful, serviceable, and safe for definite purpose. By heat treating, a metal can be made harder, stronger, and more resistant. No one heat-treating operation can produce all of these characteristics. In fact, some properties are often improved at the expense of others. In being hardened, for example, a metal may become brittle.

PROCESS FLOW CHART