Presentation on Six Month Industrial Training in HERO MOTORS

COMPANY INFOHero Motors Ltd. develop, manufacture and supply components and assemblies to automotive and white good to OEM industries. Company is committed to design, implement & comply with Quality Management Systems and ensure its effectiveness and continual improvement through active participation of all employees

Group EvolutionGroup has evolved with reliable partnerships with technology Partners, Dealers, Suppliers, Employees, Institutions and Investors. 195619781983Manufacture of cycle part and later on full cyclesManufacture of mopeds tied up with Steyr Daimler Puch in 1988 when Hero Motors was setupJV up with Honda in 1983 Hero Honda set up to start of motorcycle manufactureAuto components ancillaries started as suppliers of major components to the three Group OEM. Well established base with technology and cost leadership

1956- Set up as a bicycle Company- Hero Cycles Limited

1978- Moped manufacturing Company- Majestic Auto Limited was formed

1988- Hero Puch- Mini Motorcycle was Introduced by Hero Motors

1993- Became Indias largest Exporter of 2- wheeler.

2003- Entered into agreements with Rotax for Engine & Part Development & plant up- gradation

2006- Ferrous Casting plant at Manesar, Haryana begins Operation.

2007- Formation of JV Entity Munjal Kiriu Industries Pvt Ltd in technical collaboration with Sumitomo Kiriu Corporation, Japan for Manufacturing of automotive brake discs, brake drums and knuckles.

2010- Formation of JV with ZF Lemforder of Germany for Chassis Systems.

2010- Entered technical assistance agreement with Magna Steyr India for design and development of global recreation transmission.

2012 Tie up with Mariott Group of luxury hotels for Munjal Hospitality

Milestones

Diversified BusinessesAssimilated TechnologyHigh Growth

Hero Motors Next LevelLearnings over the past years, has got us from Formative Years to the Next Level

BRP - Shop floor best practicesBMW-Deep Supplier improvement integrationHonda Sumitomo- Lean manufacturing from the Top SuzukiZF-Organization DevelopmentReady for the scale up

Hero Motors Transmission VerticalProduct RangeGearboxGears & Shaft AssembliesEngine GearsSprocket AssembliesBalance ShaftNew Product Development

Gearbox for motorcycles,Transaxles for electric vehicles, Innovative design to cost solutions for Automated Manual Transmissions (AMT) Double Clutch Transmissions (DCT)Continuously Variable Transmissions (CVT) for passenger carsSnapshot State-of-art equipment, German and Japanese technology for Gear manufacturing.Precision technologies like teeth honing and teeth grinding are available.Technology assistance agreement with Magna Steyr IndiaApplication Engineering Centre in Graz, AustriaLeading Customers :Location : Ghaziabad

Snapshot Equipped with new generation units, the Sheet Metal Unit manufactures and supplies sheet metal parts to Hero Honda Motors Ltd. The Unit meets demand for Swing Arm, Chain Covers and Stands.Sheet Metals Press Shop has a capacity to produce 2 million chain covers per year, while Welding Facility, which has 100 MIG welding machines, has a capacity to manufacture more than 6,000 Swing arms per day.The Units Paint shop is equipped with Metal Paint shop, powder Coating Facility and Plastic Paint shop. Product RangeSwing Arm Chain CaseCylinder BlockStandsLeading Customers :DOL StatusLocation : GhaziabadHero Motors - Sheet Metal Vertical

HISTORY OF GEARS

Gears are used for transmission of power or motion . A gear is defined as a wheel with teeth cut on its rim. Gear acts and operate in pairs . engaging or meshing teeth of each other , in a pair one acts as a driver and other acts as a follower .Gears are used when the distance between driving shafts and driven shafts is very small . it is possible to drive shafts that are parallel intersecting, or neither intersecting .many different type of gears are used and their selection depends on many factors , such as the relative position of the two shafts , the power to be transmitted , in running condition

COMMONLY USED FORMSa. InvoluteThe involute tooth is derived from the traces of the point on a straight line , which rolls without slipping around the base circle . the involute system has a standard pressure angle which is 20 degree and 14.5 degree.

The involute gear are also called as straight tooth gear or spur gear and mainly used for general purpose in precision engineering due to some advantages.

COMMONLY USED FORMSb. Cycloidal The cycloidal tooth is derived from the curve which is the locus of the point on a circle rolling on the pitch circle of the gear . the cycloidal system the angle varies from zero at pitch line to a maximum at the tips of the teeth .In cycloidal system the pressure angle varies from zero at pitch line to a maximum at the tips of teeth.

The cycloidal gears are not generally used in modern engineering , but used for some crude purposes where heavy and impact loads comes on the machine.

TYPES OF GEARS

Working in Soft SectionTeeth are cut & finished in this section.The blank pieces come from vendors & are worked upon in this section.Different types of gears & pinions are constructed in this section.

BASICS OF HOBBING

GEAR HOBBINGHobbing is the fastest and cheapest system to produce gear (or every profile repeated regularly in a cylindrical surface)

HOBBING

Hobbing is the machining process for making gears, splines.The teeth or splines are progressively cut into the workpiece by a cutting tool called a hob.It is most widely used gear cutting process for creating spur & helical gears.

Working Condition

LDHob main dimensions, diameter and length, depend on many factors Characteristic of the gear (module, diameter, ..) Characteristic of the hobbing machine Type of productionWhat is a Hob Cutter?

Hob is basically a worm. The rotation during hobbing is like of a couple of worm gear and worm.Start = the profile turns around base cyclinder-axes, following a specific helix with a specific pitchWhat is a Hob Cutter?

Hob charateristic The hob is charaterized first by the overall dimension (diameter, length, bore diameter) and by the following elements:ModulePressure angleNumber of startsType of profile

BASIC OF GEAR SHAVING

Gear shaving is the most common and the cheapest finishing system of the cylindrical gear.With this presentation we will give the basic information about the shaving process.Gear Shaving

Advantage of shaving against grinding Gear Shaving Easy application of involute profile and lead modification

Short cycle time

Possibility to finish gears close to shoulders

Reasonable set-up time

Low tool cost per piece

Low investment for the purchase of a shaving machine

Easy procurement of tools

Easy automatization

Shaving process must be applied before heat treatment.

Heat treatment distortions result in errors.

The shaving result is highly dependent by the qualityof the workpiece.

Occasionally impossible to use the shaving tool on gears with a small

number of teeth.Disadvantage of shaving against grinding

BASIC OF GEAR TEETH GRINDING

GEAR GRINDING TECHNOLOGY

HISTORY OF GEAR GRINDINGIn recent years some extremely innovative gear grinding machines have come into the market both in terms of how they are constructed and of how they operate.It is a well-known fact that the two main gear grinding techniques used today are grinding using a form wheel (the profile grinding method) and grinding using a worm wheel (the continuous generating grinding method).There are advantages and disadvantages with both of these methods which may influence production times, accuracy, surface quality of the ground tooth and so on.By this presentation we will give the basic information about gear grinding operation

The most established grinding methods are:Continuous generating grinding with a worm wheelProfile grinding with a form wheel

Notes on the continuous generating grinding methodThe worm wheel can either be ceramic or CBN with a diameter that ranges from about 100 to about 350 mm.The wheel may have more than one start just like a hob. The kinematics are the same as in hobbing. This method is suitable for medium-large batch production.In general grinding times are shorter compared to form grinding if grinding gears with Z>15 but longer with Z

In worm grinding method Kinematics is the same as working with hobsX = radial feedZ = axial traslationY = ShiftingVIEW OF GRINDING BY WORM WHEEL

With form method its possible to grind also internal gears

Hard finishing External HoningGood surfaceShort cycle timeEasy to find toolsEasy to modify profile and helixKinematics is same to shaving

Internal honingGood accuracyShort cycle timeHigh cost of the toolEvery gear needs a special tool

SHAPINGIt is another machining process for creating teeth on a gear using cutter.It is a gear cutting process is in form of spur/helical gears.Internal gears can be cut with this method as well.

Operation Principle

Parts manufactured by Shaping

HEAT TREATMENTIs the controlled heating and cooling of metals to alter their physical and mechanical properties without changing the product shape.

Pre Washing

Select the Timer for Sparying of Charge as 30 Minutes. Check Skimmer Motor Working. Load the charge for Pre Washing. Monitor the Washing process through Temperature Controllers & Timers & record in Process Control sheet

Pre Heating

Set SP-1 as 450oC in Furnace Main Temperature Controller. Set Soaking time as 60 Minutes on Timer & reset the Heaters. Monitor the Pre Heating process through Temperature Controllers & Timers & record in Process Control sheet. After completion of Pre Heat Shift the Material to Sealed Quench Furnace for Next Process

Sealed Quench Furnace

Various Stages in SQF:-

CarburizingDiffusionHardeningQuenchingOil Dripping

Sealed Quench Furnace Thermal Mapping & Surface Carbon

Sample NoC%10.71520.69730.69440.68850.68360.70770.66580.68390.697Variation0.050

Sample NoC%10.72520.70930.70340.69250.71860.73470.69680.68590.693Variation0.049

Post Washing

Steps in Post Washing:-

Select the Timer for Plunging, Bottom Resting, Spray, Hot Drying, Blower & Skimming of Charge as 10 Minutes Each. Check Skimmer Motor Working. Load the charge for Post Washing. Monitor the Washing process through Temperature Controllers & Timers & record in Process Control Sheet

Tempering

Steps involved in Tempering:-

Inspection lab

Inspection Lab

Shot Blasting

PROJECT UNDDERTAKEN

SPAN SIZE VARIATION IN PRIMARY GEAR K5X

Localized Mass on PartPart No : 8530239Part No : 8530293Due to Localized Mass on Part the Overall SPAN variation was non uniform & up to 70 , due to this meeting final dimension was difficult.Problem Definition : Part No - 8530239 & 293

Reasons for variation in Case Depth

Variation in Case Depth on Mass Side and Opposite side.Carbon pickup rate is high on the mass side in comparison to opposite side as heat retention is more on the mass area.Core hardness more than specification.Hardenability band of 20MnCrS5 steel grade is J5mm =35-45HRC. Hence Core hardness can be achieved any value in between this band

Understanding of Process Flow - 8530239 & 293

Step for ImprovementStep : 1Loading Pattern Changed to keep the Mass area on Top.

Step for ImprovementStep : 3 Quench Oil Temperature raised from 110 OC to 130 O C. Step : 4 Oil Agitation changed from Continuous Agitation to Step Agitation. Step : 2 Hardening Temperature reduced from 840 OC to 820 OC.

Before ModificationAfter ModificationBeforeAfterImprovement Area

Results

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