gear and shafts
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Completed by:- Anshul Kumar NagarMechanical engineering4th year (semester 7th)
The company manufactures mainly Gears and Shaft
Standards For Gears Produced By The CompanyApplication - Engine TransmissionModule - Upto 4Diameter - Upt0 200mmWeight - 40gm - 2kgProcess - CNC Hobbing, CNC Shaving, CNC Shaping, Broaching, Bore finishing/HoningTolerances - MOT-25 Bore-20 PCD R/O-20Heat Treatment - Case Carburizing/Carbonitriding/Hardening, Tempering, controlled cooling, normalizing and annealing
Standard For Shafts Produced By The CompanyApplication - Engine TransmissionModule - Upto 4Diameter - Upto 30mmLength - Upto 180mmProcess - CNC Shaping/Thread Rolling/Induction Annealing/GrindingSpecification - MOT-25 PCD R/O-40Material - SCM415/420, High Carbon High Chrome SteelTreatment - Case Carburizing/Carbo-nitriding/Hardening & Tempering
Forge Shop Of The Company IN Shivam Autotech they see themselves as suppliers of Technology and not merely auto components. They produce auto components using the latest techniques of cold and warm Near Net Shape Forging. They ensure that the production tools and the end products are the latest in what the market has to offer, the world over. Their Production facilities are spread over various specialized areas:Chopper 200/400T (Manyo)1350 T Mechanical Press630 T Mechanical Press400 T Mechanical Press200 T Mechanical Press100 T Mechanical Press200 T Hydraulic PressInduction HeaterAuto Transfer Phosphating LineAuto Transfer Lubrite PlantShot Blasting M/C
Heat Treatment Shop In Shivam Autotech they produce auto components using the latest techniques of cold and warm Near Net Shape Forging. We ensure that the production tools and the end products are the latest in what the market has to offer, the world over. Our Production facilities are spread over various specialized areas:Batch Type Electrical Heating Normalizing FurnaceSeal Quench FurnaceHanger Type Shot BlastingVibro Finishing M/CInduction AnnealingStraightening Press
Machine ShopThey produce auto components using the latest techniques of cold and warm Near Net Shape Forging.Our Production facilities are spread over various specialized areas:CNC Turning Centres (Mazak)- 69 NosCylindrical GrinderVertical Broaching M/C (Single Station)Vertical Broaching M/C (Three Station)Helical Broaching M/CCentering & Facing M/CCNC Hobbing (Mitsubishi) 18 NosCNC Shaping (Mitsubishi/Liebherr) 3 NosCNC Shaving (Mitsubishi) 1 NosHoning M/CAWH Grinding M/C ( Inbuilt Gauging System )Component Washing M/CSPM
Tool Room Our Production facilities are spread over various specialized areas:Center Lathe (NH 22)Center Lathe (LTM 20)Cylindrical GrinderTool & Cutter GrinderSurface GrinderVertical Milling M/C Broach Resharpening M/CLapping Device (Imported)Mirror Polishing M/CMuffle FurnaceWalter make CNC Tool & Cutter GrinderVMC MAZAK Various Other Measuring Instruments like Digital Height Gauges, Micrometers, Air Gauges, Digital Vernier Calipers, Slip Gauges, etc.
Inspection And Testing Our Production facilities are spread over various specialized areas:Profile ProjectorSurface Roughness TesterMagnetic Crack DetectorBrinell Hardness TesterRockwell Hardness TesterMetallurgical MicroscopeImage AnalyzerMicro viker Hardness TesterCutting & Polishing M/CCNC Gear AnalyzerChemical LabGear Rolling TesterCMM (Zeiss) Various Other Measuring Instruments like Digital Height Gauges, Micrometers, Air Gauges, Digital Vernier Calipers, Slip Gauges, etc.
SCALE REMOVING (VIBRO):Vibratory tumbling is a great way to tumble stones, small slabs, cabochons, mix together with the scale product, to performs scale and dust removal in a short amount of time. Since vibratory tumbling gives such quick results, Use stones of the same hardness in tumbler. The tumbler bowl should be 50-75% full when loaded. Use a filler to keep stones from chipping or spalling. Water is added during this activity to remove scale from the bowl. FINAL INSPECTION:Final inspection is being done to determine whether the production process has produced the results that were desired. It is both functional and analytical. A functional check is quickly made to tell how the component will operate. OILING, PACKAGING & DISPATCH:In this process finish material before dispatch is properly oiled and packed in the respective bin for dispatch.
Operations For Shafts GRINDING (For shaft only):In general, OD grinding is performed either between centers or on a centerless grinding machine. When the features of the gear shafts require both grinding operations, they are usually done sequentially on purpose-built machine tools. Primarily a shop uses these grinding operations because of specific strengths inherent in each. For between center work, a work piece that has a critical concentric feature such as a cam lobe or gear or crank pin is processed between centers because the relative positions to the shaft diameter can be maintained. Centerless grinding, on the other hand, is best applied for creating roundness. The process is self-correcting for most out of round conditions. It is limited, however, in its ability to maintain concentricity between the shaft diameter and a lobe, gear or pin.
THREAD ROLLING (For shaft only): In this process circular thread rolling die penetrate the screw blank at a controlled rate until full depth of thread roll profile is reached.INDUCTION ANNEALING:Annealing process consists of three stages. First, the metal part is placed inside an induction coil and power is supplied until the part reaches the correct temperature. The temperature can be checked with an optical pyrometer, temperature sensing paint or some other temperature-sensing device. The second stage is holding or soaking at the correct temperature, which can be accomplished with a closed loop temperature control system. The annealed part must then be allowed enough time to cool down to room temperature.STRAIGHTNING (For shaft only):In this process we remove the bend of long shaft which occur during heat treatment process. A pneumatic press and an anvil are mounted in such a way that we apply the load opposite to the maximum bend portion.
LATEST TECHNOLOGY USED BY SHIVAM AUTOTECHNEAR NET SHAPE FORGING TECHNOLOGY
At SHIVAM they potential that are related to the new form Technology process for automotive industry, since they want to deliver the best to our customers for quality & properties of components. Our Unique Selling Proposition is that they are among the few of India's auto-component manufacturers, who use Near Net Shape Technology for high volume of production by latest technology in cold, warm & hot forging from world wide. Forging is the process of beating metal by compressing it and making it flow into the desired shape of tool or die geometry. Near Net Shape, the term implies that the die so produced is as close to the final product as is possible, leading to marginal machining allowances and greater accuracy. Forming process design via finite element simulation is the state of the art. The tribological logical conditions the knowledge of the thermal material properties as well as the knowledge of elastic & plastic mechanical material characteristics.
Advantages Of Near Net Forging TechniqueIncreased strength due to cold work & better grain flowReduction in Energy CostNo wastages of MaterialExcellent surface finish & improved corrosion and wear resistanceHigher Productivity & Reduced machining
Some Gear Manufacturing OperationsCNC HOBBING (For Gears only):Gear hobbing is an efficient method to manufacture high quality and performance toothed wheels. Worm gears are hobbed by the "tangential feed" process on specially constructed machines .The tangential feed hobbing process employs a hob made up of two elements called the "rougher" and "finisher". The roughing portion of the hob is fed gradually into the gear blank first to remove metal from the gear tooth spaces. Next, the finishing portion moves tangentially through these spaces and generates the proper profile on the gear teeth. In this phase of the hobbing operation each rotation of the hob is accompanied by a slight feed movement tangential to the gear and has the effect of progressively creating a new series of cutting edges, by relocating them with respect to the gear. The gear tooth is therefore generated by an immense number of different cuts that result in an almost perfect contour in the finished tooth.
CNC Honing Honing is a manufacturing process that produces a precision surface on a workpiece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but many also improve surface texture. Honing is classified as an abrasive machining manufacturing process. In Abrasive machining processes, material is cut away from the workpiece using abrasive grains. In the case of honing, the grains are bound together with an adhesive to form a honing stone (or hone).
GEAR SHAPING In this process the tool held in the tool holder mounted on the ram moves forwards and backwards in a straight line over the work piece rigidly held in a vice clamped over the work table. Each time the tool moves forward it cuts a sliver of metal from the work piece. Each time the tool moves backward the tool lifts clear of the work piece.
GEAR SHAVING Gear shaving is a finishing operation