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MATS Training
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Brief Information about the
companyMOTHERSON ADVANCED TOOLING SOLUTIONS LIMITED (MATS) is a significantpart in the metal division of the world-renowned group SAMVARDHANAMOTHERSON.
Motherson Advanced Tooling Solutions Limited (MATS) was incorporated byacquiring Broaches & GCT business from Dagger-Forst Tools Limited wef 01ST
June 2009. MATS are pioneers in manufacture of high quality broaches and HSSGear Cutting Tools in India. We have 4 manufacturing sites located in WesternIndia fully equipped with state of the art manufacturing and testing facilitiesincluding in-house Heat Treatment facilities. All plants are ISO 9001: 2000certified.
We are market leaders in India & also have a considerable market share in USA,Europe, RSA, Iran, South East Asia, Australia etc. Reputed automobilemanufacturers like GM, Ford, Hyundai, Eicher, Hero Honda, Suzuki and Yamaha areour valued customers along with auto component manufacturers like Dana Spicer,Fair Field, GKN and Graziano Transmissions.
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Products made in MATS
1. Hobs
2. Broach (internal)
3. Broach (flat)
4. Gear Shaver
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What is broaching ? Broaching is a machining process that uses a toothed tool, called a
broach, to remove material. There are two main types of broaching: linearand rotary. In linear
broaching, which is the more common process, the broach is run linearlyagainst a surface of the workpiece to effect the cut. Linear broaches areused in a broaching machine, which is also sometimes shortened tobroach.
In rotary broaching, the broach is rotated and pressed into the workpieceto cut an axis symmetric shape. A rotary broach is used in a lathe or screwmachine. In both processes the cut is performed in one pass of thebroach, which makes it very efficient.
Broaching is used when precision machining is required, especially for oddshapes. Commonly machined surfaces include circular and non-circular
holes, splines, keyways, and flat surfaces. Typical workpieces include smallto medium sized castings, forgings, screw machine parts, and stampings.
Even though broaches can be expensive, broaching is usually favored overother processes when used for high-quantity production runs.[1]
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ROUND BROACH
Application:
Internal :- Round, Keyway, Straight or InvoluteForm, Serration & Special Internal profile.Design Capabilities:Any Special Profilerequirements.
Material:M2, M35, M3 Type II, M42, ASP23,ASP30, CPM T15, CPM M4
Size Range:Round & Spline Dia. 15mm250mm, Length upto 2000mm Flat width 4mmto 200mm
Accuracy:Within 0.01mm
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Process followed
Raw material cutting
Pilot and taper turning
Teeth cutting Soft Machining
Spline milling
Heat treatment
Centre grinding
Rough cylindrical grinding Grinding process
Sharpening (rough) ( Profile generation)
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Gullet
Finish cylindrical grinding
Sharpening (finish)
Profile grinding
Round and flat holding Grinding process Nicking
Inspection and trial
Marking and packing
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Flat broach
Application:
External :- Connecting Rods, Turbine Blades,
Shifter Forks, Steering Racks. Design
Capabilities:Any Special Profile requirements.
Material:M2, M35, M3 Type II, M42, ASP23,
ASP30, CPM T15, CPM M4, Size Range:Round &
Spline Dia. 15mm 250mm, Length upto2000mm Flat width 4mm to 200mm
Accuracy:Within 0.01mm
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Process Followed
Raw material cutting
Width and thickness milling
Taper milling
Teeth milling Soft
machining
Extra material removing
Milling pull end / rear endHeat treatment
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Grinding bottom width
Grinding top , teeth size and taper
Grinding of angle block and keyway
Grinding profile Profile
Holding making
Nicking
Back off
Inspection
Packing
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What is hobbing ?
Hobbing is a machining process for making gears,splines, and sprockets on a hobbing machine, which isa special type of milling machine. The teeth or splinesare progressively cut into the workpiece by a series of
cuts made by a cutting tool called a hob. Compared toother gear forming processes it is relatively inexpensivebut still quite accurate, thus it is used for a broad rangeof parts and quantities.
It is the most widely used gear cutting process for
creating spur and helical gears and more gears are cutby hobbing than any other process since it is relativelyquick and inexpensive.
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Hob
Module: 0.5 M 20 M; Dia. : 50 to 250 mm
(also DP series)
Start: Single or Multi Start.
Accuracy: AA, A, B & C (as per DIN 3968)
Forms : Non-Topping, ST, T, finishing, pre-
shaving, pre- grinding, with or without
protuberance, tip relief, full fillet, etc.Material : M35, M42, ASP 30, ASP 2052, etc.
Each Item tested on Hoffler Gear Tester.
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Process followed
Raw material cutting
Facing
Drilling
Boring , Recessing
Rough turning
Finish turning Soft machining
Keyway cutting
Thread cutting
Gash milling
Releving
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Heat treatment
Face grinding
Proof diameter grinding
Bore grinding profile making
Sharpening of cutting edge
Profile grinding
Nicking
Marking
Inspection
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What is shaving
Gear shaving is basically a finishing operation.This takes place after the operations ofroughing with a hob or cutting with a shaper
cutter is over. The Shaving process consists ofthe removal of tiny particles of metal from agear teeth's working surface. Gear shavingproduces fine hairlike chips. The cutter comes
in the form of helical gear. It has specialserrations in the flank area of a gear teeth.These serrations act as the cutting edges.
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Shaving cutter
Improved surface finish of flanks and accuracies ofprofileProduce high accurate gear at low cost.Range : 170 mm to 260 mm PCD.Material : M2 & M3 (II) type of HSS material.Also carry out resharpening with profile correctionModule : 0.8 M to 6.35 M.Special design for lower than 1.50 modules.Used for finishing operation of Gears for Automobile
Transmission & other similar Engg. Industry.Each Item tested on Hoffler Gear Tester.
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Process followed
Raw material stress relieving
Drilling
Boring
Chamfering
Grooving soft machining
Facing
Turning
Rotary grinding
Soft bore grinding
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O D grinding
Hobbing
Root milling soft machiningSerration
Keyway cutting
Heat treatmentRotary grinding
Grinding bore (finish)
Profile grinding profile makingOD grinding
Inspection
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