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Transcript of gear testing
PUNJAB BEVEL GEARS
INTRODUCTION
SAHIBABADUTTAR PRADESH
4 PLANTS*
LUDHIANAPUNJAB
SITARGANJ**UTTARAKHAND
GROUP COMPANIES
DIFFERENTIAL & TRANSMISSIONGEARS andDIFFERENTIAL CAGE
FORGING MACHININGAXLE SHAFT
DIFFERENTIAL & TRANSMISSIONGEARS
*There are 4 manufacturing units located within 500 metres in Sahibabad and share common resources of Metrology and Metallurgy.
**Under Commissioning
•STARTED OPERATIONS IN 1979
•MANUFACTURES MORE THAN 2000 DIFFERENT TYPE OF GEARS
•LEADING MANUFACTURER, SUPPLIER AND EXPORTER OF AUTOMOTIVE PARTS
•CATERS TO INDUSTRIES LIKE COMMERCIAL VEHICLE, AGRICULTURAL TRACTORS, PASSENGER CAR, THREE WHEELER & CONSTRUCTION EQUIPMENT
INTRODUCTION…..Contd.
OUR COMPETITIVENESS LIES IN THE FACT THAT WE ARE :
• COST COMPETITIVE,
• QUALITY CONSCIOUS,
• HAVING TRACK RECORD OF ON TIME DELIVERY
• HAVING CAPABILITY TO DEVELOP NEW PRODUCTS IN A SHORTER PERIOD
AND
INTRODUCTION…..Contd.
• FINANCIALLY SOUND
• HAVING ASSURANCES FROM FINANCIAL INSTITUTIONS FOR SUPPORT IN THE ONGOING AND FUTURE EXPANSIONS
• HAVING VERY SOUND HR POLICIES WITH ALMOST NIL EMPLOYEE TURNOVER
• THE AVERAGE AGE OF EMPLOYEES IS 40 YEARS
•HAVING 100% CAPTIVE POWER BACK UP
• AN ISO/TS 16949: 2002 CERTIFIED COMPANY
INTRODUCTION…..Contd.
PRODUCT RANGECROWN WHEEL & PINION (Gleason & Oerlikon System)
ST. BEVEL GEARS & PINIONS (Gleason Coniflex System)TRANSMISSION GEARS
(Spur, Helical)DIFFERENTIAL CAGE
AXLE SHAFTS
FORGINGS
MACHINED FORGINGS
TOTAL SALES (Mio Rs)
404
547
764
1116
971
0
200
400
600
800
1000
1200
FY05
FY06
FY07
FY08
FY09
TOTAL SALES (Mio $)
10.1
13.7
19.1
27.9
24.3
0
5
10
15
20
25
30
FY05
FY06
FY07
FY08
FY09
SEGMENT WISE SALES FY 09
OEM (DOM)32%
OTHERS6%
EXPORT62%
OEM (DOM)EXPORTOTHERS
CAPACITY INSTALLED
Sl.No. Product Annual* New Capacity Utilization*
Capacity under of existing
installation capacity
1. Crown Wheel & Pinion 420,000 Sets 120,000 sets 70%
2. Straight Bevel Gears 720,000 Nos. 300,000 nos 70%
3. Transmission Gears 1,200,000 Nos. 400,000 nos 70%
4. Axle Shafts 60,000 Nos. 60,000 nos 25%
5. Forgings 12,000 MT -- 40%
* On 2 Shift Basis
TYPE SPIRAL/
HYPOIDS
STRAIGHT
BEVEL
SPEED
GEAR TRANS. SHAFT
MAX. SIZE (DIA) MM 500216(10:1)
152(1:1) 400 80
MAX. FACE WIDTH/L 76 50.80 400 750
MAX. MODULE (mm) 12.70 8.50 8.00 8.00
ACCURACY DIN
CLASS 8-9
DIN
CLASS 8-9
DIN
CLASS 8-9
DIN
CLASS 8-9
CAPABILITIES - GEARS
CAPABILITIES - FORGINGS
• Weight 0.5 Kg to 50 Kgs
• Round Forging Min. Dia 80 mmMax. Dia 500 mm
• Shaft Forgings Length 1200 mmFlange Dia 325 mm
SAHIBABAD LUDHIANA SITARGANJ
TOTAL AREA 500,600 152,500 183,140
COVERED AREA 179,390 46,000 95,200
GENERAL OFFICE AREA
5,420 5,000 11,600
PLANT AREA IN SQ. FT
Sahibabad LudhianaSitarganj (Planned)
Hourly 435 65 100
Supervisory 47 07 12
Manager 13 01 02
Total 495 73 114
MANPOWER
PUNJAB BEVEL GEARS LIMITED ( AN ISO/TS 16949: 2002 COMPANY)
(Excluding Product Design)
RECOGNISED STAR EXPORT HOUSE AWARDED SILVER SHIELD FOR EXPORT
PERFORMANCE DURING 2005-06 BY EEPC
CERTIFICATION
CNC Turning Lathes 22 Nos.
Vertical Machining Center 03 Nos.
Gleason Crown Wheel 8 Sets(608/609, 606/607, No.11 & No. 22)
Gleason Pinion 7 Sets(No.116 & No.16)
Oerlikon 9 Nos. (SM3, S17, SKM1)
CUTTING EQUIPMENT INSTALLED
Transmission Gears Hobbing 26 nos
Shaping 26 nos
Shaving 14 nos
Straight Bevel Gears Gleason Coniflex114 02 nos
Gleason Coniflex104 02 nos
Coniflex WMW 26 nos
CUTTING EQUIPMENT INSTALLED
HEAT TREATMENT FACILITIES
Sealed Quench Furnaces
Continuous Gas Carburising Furnace
Gas Carburising Furnaces
Rotary Hearth Furnaces
Pusher Type Furnace
Quench Presses – Oerlikon, Klingelnberg, & Gleason
Tempering Furnaces
Manganese Phosphating Facilities
Shot Blasting Equipments
Straightening Presses
•Cylindrical Grinding Machines -10 Nos.
•Internal Grinding Machines - 5 Nos.
•Spline Grinding Machine - 1 No.
•Lapping Machines•Gleason - 11 Nos.(503/506/119/513/516)
•Oerlikon (SKL-1) - 1 No.
•Gear Testers-Gleason - 13 Nos.(502/511/17-A)
FINISHING EQUIPMENTS
Full range of Hardness Testers
(Rockwell, Brinell, Vickers, Micro Vickers)
Hardenability (Jominy) Apparatus
Microscope with camera and image analyzer
Crack detection Equipment [Magnaflux]
Macro Etching
Manganese Phosphating Solution Analysis
Muffle Furnaces
Sample Cutting / Polishing Machines
METALLURGICAL LAB FACILITIES
Includes:
• CMM with Gear Analyser
• Lead and profile testers
• Surface Roughness tester
• Contouro Graph
• Profile Projectors
• Digital Temperature Calibrator
•Wear Check Plug for Thread Ring Gauge Calibration
METROLOGY LAB FACILITIES
RAW MATERIAL
Forgings are received Heat Code wise duly
Isothermally Annealed/ Normalised.
Checks before processing are:
• Visual Inspection for cracks and folds.
• Check of chemical composition by Spectro Analysis.
• Hardness.
• Jominy Hardenability.
• Micro structure and Inclusions.
• Grain Size and Grain flow.
QUALITY SYSTEMS
IN-PROCESS
First off inspection &
Patrol inspection at defined interval as per control plan
For Bevel Gears check tooth contacts in soft Gears
Before Heat Treatment inspection for all parts ensuring removal of any sharp edges and burrs.
For Bevel Gears Final Testing to ensure backlash at correct mounting distance, tooth contact, run out and marking mounting distance variations.
QUALITY SYSTEMS…….Contd.
HEAT TREATMENT
Batches are subjected to checks on:
Effective Case Depth
Core and Surface Hardness
Microstructure- Case & Core
Flatness & ovality of bore for Crown Wheels
Straightness for Shaft items
Magnetic particle inspection by Magnaflux
QUALITY SYSTEMS…….Contd.
•Additional Continuous Gas Carburising Furnace
•Sealed Quench Furnaces
•CNC Hobbers
•CNC Shapers
•CNC Shavers
•CNC Internal Grinder
•CNC External Grinders
•CNC Gleason/Oerlikon, Dry/Wet Cutting System for Crown Wheel & Pinion (under consideration)
INVESTMENT COMMITTED
CUSTOMER PROFILE – DOMESTIC OEMsAUTOMOTIVE
•TATA MOTORS
•MAHINDRA & MAHINDRA
•DANA INDIA
•SCOOTERS INDIA
•AMERICAN AXLE &MANUFACTURING
CUSTOMER PROFILE – DOMESTIC OEMsAGRICULTURE
•TRACTOR & FARM EQUIPMENT
•INTERNATIONAL TRACTORS
•JOHN DEERE EQUIPMENT
•NEW HOLLAND TRACTORS
•INDO FARM EQUIPMENT
•STANDARD COMBINES
CUSTOMER PROFILE – DOMESTIC OEMs
CONSTRUCTION EQUIPMENTS & OTHERS
•JCB INDIA
•TELCO CONSTRUCTION EQUIPMENT
•ACTION CONSTRUCTION EQUIPMENT
•EICHER MOTORS
CUSTOMER PROFILE – EXPORT OEMs
•UZEL MAKINA SANAYI A.S., TURKEY
•MEGA MOTORS COMPANY, IRAN
•IRAN TRACTOR MFG COMPANY, IRAN
•ARVIN MERITOR, BRAZIL
We also Export our products to Importers, Gear Makers & After Markets in:
USA , U.K., France, S. Africa, Indonesia, Malaysia, Thailand, Singapore, Burma, Syria, Egypt, Turkey, Bangladesh, Sri Lanka, Iran, Dubai, Italy, Argentina, Australia, Hungary, Germany, Brazil etc.
CUSTOMER PROFILE - EXPORTS
FORGING FACILITIES AT LUDHIANA
• Friction Belt Drop Hammer (1.00, 1.50, 2.00, 2.50, 3.00, 6.00, 8.00 M.T.)
• Up Setter - 3 Inches & 6 Inches
• Furnaces for Isothermal annealing & normalizing
• Fully equipped die making facilities
• Material testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines
• 100% back up with Captive Power
• An ISO 9001: 2008 certified
FACILITIES AT SITARGANJ
• Green Field Plant having shed & flooring ready
• Continuous gas carburising & sealed quench furnaces under commissioning at site
• Cutting equipments identified & under movement to site
• Key personnel identified
• Production expected to start in December 2009
• Production & capacity planned
• Crown Wheel & Pinion- 120,000 Sets• Straight Bevel Gears - 300,000 Nos.• Transmission Gears - 400,000 Nos.
PUNJAB BEVEL GEARS LIMITEDB-44/1 & 52/2, Site-IV, Industrial Area,Sahibabad-201010, Ghaziabad (U.P) IndiaTel.: +91-120-2895386/2895320/2896075/2895344Fax: +91-120-2896099/2896059Email: [email protected] Site: www.punjabbevelgears.com
PLANT ADDRESS