Summer Internship

Parveen KumarB.Tech(me) 5th sem

A501054140292014-2018

Summer InternshipAt

LOTUS AUTO ENGG. LTD.BHIWADI, RAJASTHAN

UnderProject

OfRING GEAR PRODUCTION

From20-05-2016 to 05-07-2016

ContentABOUT LOTUS AMTEK AUTO LTD.OBJECTIVES OF THE STUDY &

LITERATURE REVIEW RING GEARRING GEAR PRODUCTION LINE

LOTUS (AMTEK) AUTO LTD. Amtek is a leading multi-national manufacturer of automotive components and assemblies

with production facilities located strategically across Asia, Europe and USA. The Group’s extensive manufacturing capabilities encompass Iron and Aluminum Casting, Forging, Machining & Assemblies.

Amtek Auto Ltd. has established itself amongst the top players in the Indian auto ancillary industry and has also grown to become one of the largest manufacturers of Forgings, Castings, Machined Components and Assemblies, which includes Piston Connecting Rod modules and Gear Shifter Forks and Yokes, Flywheel Ring Gears in the country. Amtek also holds the distinction of being among the largest manufacturer of Flywheel Ring Gear Assemblies and Turbocharger Housings in the World. The Group's extensive manufacturing capabilities encompass Sub assemblies, Iron, Gravity & Aluminum Castings, Forgings, Complex Machining & Ring Gears Flywheel Assembly.

AAL entered into a joint venture with Benda Kogyo of Japan to form Benda Amtek in 1997 for manufacturing of flywheel ring gears located Gurgaon. Later, in 1999 the company entered a JV with Ateliers de Siccardi to form Amtek Siccardi for manufacturing crankshafts at Manesar. In 2001 the company acquired auto component manufacturing firm Wesman Halverscheidt Forgings. The same year it also acquired Indusial Auto components Coimbatore (India).

In 2002 the company established an iron casting facility at Bhiwadi. The same year AAL acquired 14.8% equity stake in Ahmednagar Forgings. The next year in 2003 the company acquired an additional 20% stake in Ahmednagar Forgings.

LOTUS (AMTEK) AUTO LTD.Different divisions of the company are: Amtek Centre of Excellence (ACE) Amtek Forging Division (AFD) Amtek Iron Casting Division (AICD)Amtek Aluminum Casting Division (AACD) Amtek Automotive Machining Division

(AAMD)Amtek Ring Gear Division (ARGD) Amtek JVS

Business Divisions Forgings: - Forging is the process of forming hot / cold metal. The Forging divisions of the group are Baddi

(H.P). Connecting Rods, Crankshafts, Steering Knuckles, Gears shifter Forks, Sector Gears & Shafts, Stub Axles, Front Impact Beams etc. are some of the products in the Amtek Forging suite.  

Castings: - Casting is the process of forming from molten metal. The Group has facilities for Iron Castings

at Bhiwadi (Rajasthan), Baddi (H.P), Coimbatore (Tamil Nadu) & Tipton (UK). Besides Iron Castings, Amtek has facilities for Aluminum Castings at Bourne (U.K) and is in the process of commissioning another Aluminum Casting facility at Ranjangaon (Mah.).

Machining:- Machining is the term used for a set of metal – cutting processes which are performed on

Forgings and / or Castings to give them the exact shape and size for assembling in the vehicle. The Group has Machining facilities within India at Gurgaon (Haryana), Sanaswadi (Mah), Manesar & Dharuhera (both in Haryana), Baddi (H.P), and across the World at Letch worth, Coventry & Bourne (in U.K) & Hennef (Germany), Stanberry, Bay City & Kellogg (in USA).

Assembly: - The Assembling activities are carried at Letch worth, Coventry, Gurgaon, Dharuhera, & Hennef

(Germany). The products include Bridge Fork Assemblies, Strut Assemblies, Wheel Corner Modules, Axle Assemblies, Turbochargers, Piston Cylinder Modules, Spindle Assemblies, and Fuel Delivery Systems.

MANUFACTURED PARTS Amtek product portfolio consists of an extensive

range of components for 2–3 wheelers, Car, Tractors, LCV, HCV and Stationary engines. The major categories of components manufactured are,

Connecting Rod Assemblies Flywheel Ring Gears and Assembly Steering Knuckles Suspension and Steering Arms CV joints Crankshaft Assemblies Torque Links

OBJECTIVES OF THE STUDY & LITERATURE REVIEW

The main objective of the Training is to study the Production process of the Amtek MAGNA Powertrain Ltd. And to analyses the Production process and defects of the Amtek MAGNA Powertrain Ltd... The study includes the study of all control plans of the products and machining processes etc. The main objective in working with the production process is to calculate the production rates with in time and without any defects.

My duty in company was to understanding and studies the production of Ring gears process. Lotus AMTEK deals with the production or machining of ring gear. It is a joint venture of Amtek group

RING GEARDEFINITION:- A starter ring gear, sometimes called a starter ring or ring gear, is a medium carbon steel ring with teeth that is fitted on the periphery of a flex plate or flywheel of an internal combustion engine, mostly for automotive or aircraft applications. The teeth of the starter ring are driven by the smaller gear (the pinion) of the starter motorManufactureThe starter ring gear is most commonly made by forming a length of square or rectangular steel bar into a circle and welding the ends together. There then follow various operations such as normalizing (to remove stresses and improve the properties in the weld area), turning, generating the teeth by gear hobbing and finally a heat-treatment operation(s). The teeth of the starter ring need to be hardened in order to increase their strength and resist wear. The normal hardness at pitch circle diameter is 45-55 HRC. The body of the ring is generally left untreated which gives some ductility for shrinking onto a flywheel or welding to a flex plateAttachmentThe interference fit renders the starter ring firmly attached to the flywheel.Engines with automatic transmissions instead have a pressed steel plate with the starter ring gear usually welded onto the outside of the plate

RING GEAR PRODUCTION LINERing Gear Manufacturing Process RAW MATERIAL (Trapezoidal Bar Of Alloy Steel)

INWARD INSPECTION (To Verify The Dimensional And Metallurgical Parameter )

BLANKINGMACHININGHOBBINGCHAMFERINGWASHINGINDUCTION HARDENINGFINISHED COMPONENT

RING GEARDEFINITION:- A starter ring gear, sometimes called a starter ring or ring gear, is a medium carbon steel ring with teeth that is fitted on the periphery of a flex plate or flywheel of an internal combustion engine, mostly for automotive or aircraft applications. The teeth of the starter ring are driven by the smaller gear (the pinion) of the starter motorManufactureThe starter ring gear is most commonly made by forming a length of square or rectangular steel bar into a circle and welding the ends together. There then follow various operations such as normalizing (to remove stresses and improve the properties in the weld area), turning, generating the teeth by gear hobbing and finally a heat-treatment operation(s). The teeth of the starter ring need to be hardened in order to increase their strength and resist wear. The normal hardness at pitch circle diameter is 45-55 HRC. The body of the ring is generally left untreated which gives some ductility for shrinking onto a flywheel or welding to a flex plate

RING GEAR PRODUCTION LINERing Gear Manufacturing Process RAW MATERIAL (Trapezoidal Bar Of Alloy Steel)

INWARD INSPECTION (To Verify The Dimensional And Metallurgical Parameter )

BLANKINGMACHININGHOBBINGCHAMFERINGWASHINGINDUCTION HARDENINGFINISHED COMPONENT

PRODUCTION PROCESSRing Gear Manufacturing 1. Blanking: Blanking process the rolling of a

straight trapezoidal bar of steel into a coiled form; slitting the entire coil at a point to separate each steel loop of the coil which in the form of ring but silt at point; flash butt welding together of the separate end of the loop together to form a complete ring; removal of extra welding flash from the ring.

PRODUCTION PROCESS 2. Machining: the machining processes involved is

turning. Basically the turning operation on a ring is done in two steps. In the first step & the internal diameter is turned to specific size and surface finish. The cycle time to this operation is varies between 1-1.5 minutes depending on the size of the ring. In the second step outer diameter & outer face is turned and the cycle time varies between 1 - 1.5. 

PRODUCTION PROCESS 3. Hobbing: The term hobbing is refer to the process of

cutting the outer diameter of the machining ring into the shape of gear teeth by a specially designed cutting tool is called the hob cutter. The profile and the shape of the cutter on the hob. Gera hobbing is performed on special purpose machine called the gear hobbler.

PRODUCTION PROCESS

4. Chamfering: In the chamfering process the sharp edges of the gear teeth on the clutch side of the gear are removed to facilitate easy engagement of gear teeth with the pinion gear of the electric starter motor of the engine as to avoid any kind of friction, which may occur otherwise during actual use. The approx. cycle time of the operation is between 50sec -120sec depending on the component.

PRODUCTION PROCESS 5. Debarring & washing punching: In the process the loose chips of the metal which may have stuck of the ring are removed and the gear are washed using antirust oil. This operation takes around one minute. Punching of the batch code and the supplier code is a lose done after this process

PRODUCTION PROCESS 6. Induction hardening: This is the operation of

raising the surface hardness of the gear teeth up to a specific level and the depth of the hardness is also controlled to achieve a specific case as per the design requirement of the costumer.

THANKS