Project Mba Report

7/30/2019 Project Mba Report

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CONTENES

1.Acknowledgements

2.Certificate

3.HM- Company Profile

4.Introduction

5.Problem Definition &Initial Trials

6.Heat Treatment Process

7.Fishbone Analysis

8.Conclusion


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CERTIFICATE

THIS IS TO CERTIFY THAT MANISHA SURESH

SONAR HAVE COMPLITED

A PROJECT ON BENDING IN CLUSTER GEAR

SHAFT ANALYSIS AND SOLUTION ;

As a part of her training at A.V.TECH,LTD

PITHUMPUR FROM - 5MARC 2013 TO 5 APRIL

2013AND HER PERFORMED SATISFACTORILY.

PROJECT GIDE

N. K. RAO.

D G M QARD,

AVTECH LTD PITHUMPUR.,


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ACKNOWLEDGEMENTS

I Would like to express my sincere gratitude towards

Mr.N.K.Rao,(DGM,QARD)Hindustan Moters Limited,Pithampur for allowing me to

undertaken this project.It has been an absolute pleasure to be associated with

him.I think him for his constant guidance and enlightening insights during my

short sojourn.

I would also like to thank Mr.Prashant Sarvastava(HEAD,training Center)for this

help.I am immensely indebted to Mr.D Ghoshal,Mr.S.SARAF and Mr.H. Srivastava

(members of Heat Treatment Cell) for their guidance,support and continuous

efforts without which the successful completion of this project would not have

been possibal .

In the end, Iwould like to express my gratitudetowards all the operators,security

personnel and HR personal who have directly or indirectly contributed in my

project wok.


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HINDUSTAN MOTORS LTD.

COMPANY PROFILE

Hindustan Moters Ltd.pioneers in the Indin Automobile sector is one of the

G.P.Birla&C.K.Birla groups of companies.The company came into existences in

1942 at Port OKHA. Later the company was shifted to Uttara (W.B)near

Kolkata.In1944-45 the company entered into collaboration with Nuffield Org. of

England& started manufacturing Indian model of Moters cars. In subsequent

years it kept on giving different models: viz Hindustan, Hindustan Land Master M,

Hindustan Traveler, Hindustan Ambassador, mark 1to4, Ambassador

Nova&Contessa 1to the Indin customers.

Various Divisions Of HM

Name

div.

Yea

r

Located

At

Present

Collabor

ators

Products

Manufactured

Hind Moter

Div1942 Uttarpara,

West

Bengal

NONE Passenger

Car

Power

products

Div

1983 Hosur

Tamilnadu

Allison,USA

Twin

Disc,USA

Power

Shift

transmissionPower

Unit Div.

1984 Indore

M.P.

Isuzu,japan Diesel, Petrol &

transmission for

Ambassador&

Contessa


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1997 Indore

M.P.

Mitsubishi

Motors Crop

Japan

Lancer Car

Engines&

transmissions

ChennaiCar Plant

1997 ChennaiTamilnadu

MitsubishiMotors

Crop, japans

Lancer Car

RTV 1998 Indore

M.P.

OKA Motors

Crop,Austral

ia

RTV

manufacturing&

assembling.


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THE POWER UNIT PLAt

The power plant of hml, which was initially the passenger car divisions was

established in 1984 the division comprised of state of art manufacturing. Thedivision complex, manufacturing fuel-efficient engines and transmission, basically

for passenger car application the division spread over an area 153- hectare. The

the total investment in the divisions including the machinery amounted to around

s- 1840 million. The main Assimilation of technology from Isuzu Japan.

The production in the division commenced from 1987. At present plant has

manufacturing capacity of 15000 power unit per annuam. The division can boast

of ultra modern research and development facilities for design can boat of ultra

modern research and development facility for design, development and testing of

engine and transmission. The division also caress out systematic training program

and in 1995-1996 the division achieved 4 mansday of training per employee per

year.

During their journey owards excellence him, pithumpur got iso9001 accreditation

in 1994, in addition to this they were certified as iso9001 accreditation in 1994. In

addition to this, they were certified as Iso14001 Company for their environmental

management system implementation in November 200. The journey for

excellence system implementation in November 2000. The journey for the

excellence continues with the effort in embracing total productive method as a

religion with the effort in embracing total productive maintenances as a religion

in addition to institutionalizing qs9000 standards.


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Introduction

by Hindustan motors ltd. KNOWN AS THE CLUSTER GEARS SHAFTS . YHE c.g.s. THE c.g.s IS A

PART OF THE TRANSMISSION ASSEMBLY ASSEMLED IN H.M. LTD, PITHUMPUR FOR MAHINDRA

AND MAHINDRA The focus of my project is a component manufactures BOLERO.

THE MANUFACTURING PROCESS OF c.g.s. involves the following steps.

1- Forging- the shaft is forged at HMS uttarpara plant situated in west Bengaland sent to pithumpur for further processes.

2- Machining- the various machining operation that are carried out on theforged shaft are 1- facing and cent ring , 2- turning,3-thread cutting , 4-

gear hobbling & shaping, 5- splint rolling- , 6- gear shaving. All the above

operation are carried out on cnc machine.

3- Heat treatmentthe heat treatment procesis is the most important stepin the manufacturing of cluster gear shaft, since it is this stage which

imparts the component the required strength need to withstand normal

and terosinal stress of varying magnitude, to which it is subjected. This

phase basically consist of the fooling step which have been discussed in

detail since this is the main area of my study 1- carburizing and hardening,

tempering.

4- Hard grinding- after the heat treatment process the cgs is sent for hardgrinding. This is the final machining operation before the C.G.S. is sent for

assembly. This stage ensures the desired surface finish on the component

5-


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Heat treatment process-

The fooling text contains a study of the process to which the cluster gear shaft is

subjected in the heat treatment shop. The list of processes is under-

1- Prewashing2- 2- carburizing and hardening,

3- 3- post washing4- 4-tempering;

5- - shot blasting,6- Straightening

7- Induction annealing.1- Prewashing this phase is carried out to free the

component from oil, dust and any undesirable surface

deposit. The process is carried out in a specially designed

washing Mac to 1 hr to be complied.

2- -carburizing &hardening- carburizing is the absorption anddiffusion of carbon in to solid ferrous alloy by heating to a

temperature usually above Ac3 fec diagram in contact with

a suitable carbonaceous material gas carburizing usesCARBON FROM A HYDROCARBON GAS AND EASILY

VAPORISED HYDROCARBON LIQUID O PRODUCE A HARD

SURFACE on steel mpart . The main function of carburizing

is to produce a hard surface layer on steel part. The main

function of gas carburizing is to be providing adequate

supply of carbon for absorption and diffusion into the steel.

a common commercial practice is to use an endothermic

gas is carrier that is enriched with one of the hydrocarbongases the atmosphere inside the furnace is combustible

and toxic while the medium reducing. Hardening means

increasing the hardness by a suitable heat treatment

process which involves heating the components above the

austenising temperature for a certain pre-determined


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period of time and then rapidly cooling it by quenching it

in suitable the result obtain are unsatisfactory as far as

he improvement in the value of bending in the cluster

gear shaft is concerned, as percentage improvement in the

result is almost negligible we may infer that the changing of

oil has not shown any improvement in bending however

the shaft cell reported an improvement in the lead profile

which was positive sign.

3- 4- priestesses- one of the causes of bending can beattributed to the pre-stress in the component developed

during the additional stress during the machine stage. The

forged components supplied the company not normalized

as per the specification of the input material. As the

component pass through various machining operation

these stress are compensated during quenching in the from

of bending and distortion.

4- To prove the fact we conduct 2- trials in which the changewas pre- heated to relive any forging or matching stress

before being subjected to hardening and quenching the

experiment was carried out on charge no 8192/8198 thepreheating carried out in tempering furnace at a

temperature of 500.dc, for a duration of 60min. the result

of the trials are attached in the fooling pages

5- D. METHOD- analysis these variable- i- time, temperature,and pressure- the time temperature for various processes

is already specified on the process sheaf and is proved to

be correct the prescribe time , temperature and pressure

are mentioned on various machine the case depth andhardness values thus obtained are within specification.

6- Quenching process- large bending stresses are generatedduring quenching since. The component at very high

temperature 920 dc is suddenly cooled. The causes

distortion in component, in earlier trials to study the effect.


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Slow quenching was also done but this did not yield any

encoring result, so was ruled out. Flow quenching oil into

the f/c may have some effect on bending. So to get a

uniforms flow over components, additional guard besides

the fixtures was put inside the machine, even this did not

produce any improvement in terms of reduced distortion

so this factor was ruled as well. Quenching oil- one of the

possible reason for increasing bending could be attribute to

the quenching oil being used. in one of the earlier trials in

conducted at hm , a step was taken to change the

quenching oil altogether these the older mt-355 was

replaced by an oil- vedol quenching hm, thus is more

viscous than the former

7- Ch no 5359 mt-355- oil charge qty-77 no.8- Range mm no of compo % remark.9- 0.00-0.06 18 23 good10- 0.17-0.10 18 23 fair11- 0.11-0.15 13 16 bad12- >0.15 28 36 very bad13- Visual case depth- 0.6-1.0 mm. microstructure- case- finetempered mrtensite, no carbide network allowed. Retain

austenite, 40% maximum, and core- low carbon tempered

martensite lctm + bainite.

14-15-16-17-18-19-20- Medium. Case hardening is generics term covering several

processes applicable to steel that change the chemical

composition of the surface layer by absorption of carbon,


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nitrogen etc. the process used for doing case hardening

involves carburizing followed by quenching.

21- Initial trials- we conducted 3 trials initially on chargenumbers 8160,8162,8163 with a view toa- learn more

about heat the treatment process under studys- get an

insight into the nature of the problem and the variable

concerning it . the result of the run outs observed on the

cluster gear shafts in these trials have been attached in the

subsequent pages they have been summarized as under.

Trial charge no no of components Avg run out

1 8160 77 0.17mm bad

2 8162 77 0.147mm bad3 8163 77 0.15mm bad

THE AVERAGE RUNOUT AT SECTIONSA In cluster gear shaft of all 3 trials was

found to be 0.155mm or 155 microns which is well above the specified tolerance

of 0.04mm or 40micron. A runout of this magnitude required considerable

prevent this problem occurring that the heat treatment stage.straighting action o

brings the component within the specified limits. Which is not advisable? Since it

may damage the shaft .hence it is of utmost importance to

Note- it nuts be noted the forging applied to H.M. As against being normalized

xcm318 harden and tempered forging of a required material is supplied.

c- Jigging and fixtering- the fixture which the component mounted may be faulty

the fixtures may have bends in themselves or the initial mounting may be

incorrect, but the fixtures have been thoroughly cheacked for such inherent faults

and any such possibility seen ruled out.

Gauges /calibrations- various gauges on different machine are checked for

performance. Monitored and calibrated on regular basis. Therefore this factor

canbe ruled out as a possible cause of bending.


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Condition of fixture- various possible activity is carried out observe no issue.,

furnace and heating pattern - one of the possible causes for large magnitude of

distortions, / bending during heat treatment can be non uniform heating in sealed

quenching furnace this result in to localize thermal stress which are ultimately

compensated in bending.

This fact had to be suited in depth so as to evaluate its validity. In the given

context. We conclude three trials chq no 8163, 8192, 8198, and drew up location

wise bending pattern for each charge. these pattern have been attached pages,

when the pattern have been attained in the subsea pages, when these pattern

were studied for any observable trends that indicated any discrepancy in the

furnace heating pattern they did not revel any such trend thus we conclude that

the furnace were functinating normally and the problem being discussed couldnot be the functioning normally and the problem being discussed could not be

attribute to them.

Problem definition-it has been observed thatduring the heat treatment processthe cluster gearshift undergoes bending of the order of 150-200 micron. 0.15 to0.25 mm. as against specified tolerance. Of 40 microns 0.04. a measurement of

runouts of components before and after heat treatment process, illustrate this

fact. These bending make it necessary for a large amount straightening operationto be carryout since apply high lod is not avlable and its twist and effect the

component. Adversely hence it is very important that is bending remove, the

cluster gear shaft is a critical component of the transimation assembly and any

short case in its quality is reflected on the functioning of the entire unit./, our

project task would be study the heat treatment process , they various factor

concerning and affecting it, identifying the possible reason for bending and

suggesting measure to eliminate it.

Summary of result-

the result of run out at section a 0f

charge nos- 8192/8198 are summarized as below.


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Trial ch.no. no of comp avg-runout comment

4 8192 47of 77 recorded 0.073mm very good

5 8198 77 0.061 very good.

The average run out of stress relive cluster gear shaft was found to be 0.067

microns. In comparison to our initial trials where the avg run out 0.155mm, we

see a 56.7% reduction in the run out. Section a

As it is evident the next page which illustrate, it is worth nothing in the ch no

8198, sixe component 8198. Sixe components were such that they did not require

any straightening action at all. These are very positive sign which were not

observe earlier.

FISHBONE ANALYSIS

The fish bones analysis is done on the basis of four aspects that govern a

components process of manufactures. As depicted in the diagram, the fishbone

analysis for cgs is follows-

a- Man- loading-The loading of components is performed by unskilled operators. Since

before being loaded into the furnace, the arrangement is cross checked for

correct loading style and pattern, thus the possibility of this fact being

responsible for bending is ruled out.Further, if this was the reason

responsible for increased bending than it would have been observed only in

a few components which had been erroneously loaded, but repeated

bending discards mishandling as a cause.ii. Monitoring

Although most of the controls are electronic and automatic, but human

supervision is essential to ensure problem free running of the process. If

lack of monitoring had been the reason for increased bending then it would


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have been observed only in a specific charge, but repeated patterns

eliminate this as one of the probable causes of bending.

iii.STRAIGHTENING

The straightening operation is one operation which relies heavily on the skill of

the operator , but since the bending occurs before the operations i.e. during heat

treatment hence these bending occurs before the operation i.e. during heat

treatment hence these bending occur before these operation i.e. during heat

treatment hence these bending cannot be attribute to these operation mistake

can be made during measurement of run outs but practically this will not lead to

error of the magnitude. But practically this will not lead to errors of the

magnitude.

b- Material-c- Composition- the material specification for cluster gear shaft is as follow

material xscm318 low carbon alloy steel , input specification, annealed/

normalized 160/220 b.h.n out put specification- surface hardness 58

h.r.core hardness 30-45 hrc , effective case depth, 0.5-.8 mm.

d- Fishbone digram:-

Material man

Composition loading

Straightinig

monitoring

Time/tmp/pressure bending in c.g.s.

Time/ temp/pressure fixtures sqf/c heating

pattern


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Quenching process gauges condition of machine

.quencing oil used


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1- Every components is checked for the magnitude of distortion bending it hasundergoes during heat treatment this is done by measuring run out at

section a , c. b. , dial gauges with a least count of 0.01 mm i.e. 10 micron are

employed for these a common trends has bents section that the run outs

increases dia the run out is seen to be increasing , second step of

straitening operation is to apply mechanical load on the bent section

primarily section b & c to minimize the run out so that component fall

within the specified tolerance the load is usually not applied on section a

which being greater in cross section is susceptible to d damage.

2- These straightening machine used is based on hydraulics control and hasbeen manufacture by galdabini Italy. The machine has max load capacity of

50 tons. But the maximum load during the straightening of cgs is kept 5 tons.

It must be noted that he straightening operation is largely depends on the

operators skills. It always advisable may handle the operations.

3- Induction annealing- the last operation on the cgs involves the localizedheating in threaded portion of the mentioned area by means of electrical

induction to a certain temperature followed by gradual cooling in air

annulled is carried out to soften the threaded portion, the induction

annealing machine has been made by ema- india.after induction annealing

the component is sent for hard grinding before finally being dispatched forassembly.

4- Conclusion-5- After studying the result of trials, we can conclude that stress reliving the

components has yielded good result. Thid illustrate the fact that the

component yielded extremely good result. The illustrates the fact that the

components carry a large magnitude of machining stresses prior to heat

treatment.


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Project Mba Report

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