Implementation design for inspectionof O-rings

Under Guidance ofMr. SUFIAN JALILIMANAGER (QA)TML DRIVELINES LIMITED

Under Advisor of Dr. B.KONDA REDDYASST. PROFESSORRGUKT

A summer intern project by S. KESAVULU R101276

Gear box assembly process block diagram

Problem statement: Leakage due to O rings Objective: Design, Manufacturing a Gauge Observation: Gear box assembly line there are some leakage problems

due to O rings defects and improper fitment

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9 Speed Synchromesh G1150 Gear box

Features of G1150 Designed for higher reliability - Profile Ground

Gears Five planet range gearing design for higher

capacity rating Weight without oil(kg): 220 Speedo sensor: std magnetic pick up Application: Truck

Problems Facing due to O-Rings in Gear box assembly: Proper fitment, Missing of O ring, Dust on O ring, might be cut , fitting of elongation or compressed O ring

Description of O-Ring• Mechanical gasket in the shape of a torus• designed to be seated in a groove and compressed during assembly

between two or more parts, creating sealant the interface• Relative motion between the parts and the O-ring• They can seal thousands of pressure.

Manufacturing methods: Extrusion, Injection O ring Material Viton: Synthetic rubber Shore hardness: Testing of hardness Sizes Surface finish Functions and Applications of O rings

• Contact stresses increases by increasing pressure

• It has point contact between o ring and sealing faces, allows high pressure, stress without exceeding the yield stress

O rings are not in exact dimensions, their size should be in specified tolerance zone

Quality standards: Check the condition of O ring, proper fitmentInspection Methods of O rings Visual examination and inspection steps

Fig: Cross Section of O ring

Table: TML Drivelines ltd mainly used O-ring sizesO RING PART

NOCS mm ID mm

271526207704 1.8 9.3271526207709 2.65 12.37271526207707 1.8 17.17271526207703 2.65 20.3271526207705 2.65 21.69271526407702 3.55 60 271526207702 5.3 66.04271526207706 3.53 66.21271526407701 3.53 72.62271526207708 1.8 82.27

O-Rings used in Gear box Assembly• O-ring can be inserting into the planet carrier spacer

assembly• Assembly of rear housing• assembly of piston cover.• Inlet pump housing (IPH),Oil pump plate, Oil gallery hole

Design of Taper MandrelFor sizes of ID are 9.3mm and 12.37mm. After considering the tolerance, tolerance is +-0.2 in the range of 6-30mm of ID.For ID of 9.3mm:

Maximum limit is – 9.3+0.2 = 9.5Minimum limit is – 9.3-0.2 = 9.1

For ID of 12.37mm: Maximum limit is – 12.37+0.2 = 12.57 Minimum limit is – 12.37-0.2 = 12.17

Conclusion Taper mandrel gauges are exclusive for given 10 different sizes of O rings This taper mandrel gauges measure actual dimension of O ring within

tolerance limits quick results with the specified tolerances Time involved in for inspection is reduced

Laser Marking• Clearly visible, permanently marked, HD marking, Durability• Precise beam positioning and a beam highly localized energy transfer to the work

piece

Tata motors

TML Drivelines

Axels and Transmissio

nsTata Motors mission statement

Technologies & equipment for machine shop, heat treatment, assembly, forge, laboratories and ERC Proto shop

Gauge and Gauge design In mass production instead of measuring actual dimension of each part the conformance of the

part with tolerance specification can be checked by Gauges. whether the inspected part has been made with the specified limits Differ from measuring instruments they are specially made for some particular component,

which is sufficiently large quantities quick results with the specified tolerances Time involved in for inspection is reducedLimits and Tolerances: Dimension of the manufactured part can only be made to lie between two limits, maximum and

minimum The high limit (upper limit) for that dimension is the largest size permitted and the low limit is the

smallest size permitted for the dimension. The difference between the upper limit and lower limit of a dimension is “Tolerance Zone” Accuracy and Perfectness

About TML Drivelines Company profile Machining process involved in gear box Objective of project Introduction about gauge and design Procedure(Including O rings) Design of Taper Mandrels Laser Marking Conclusion

WCQ

Built in Quality

Don’t accept, build, ship a

defect

Create Customers in Enthusiasm

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