INDUSTRIAL TRAINING

AT
GAJRA GEARS, DEWAS

Submitted to:

Submitted by:
Arup Biswas

ACROPOLIS INSTITUTE OF TECHNOLOGY & RESEARCH, INDORE

SESSION 2012-2013

Group Mission:
To transcend to new heights of being recognized as a World Class Gear Manufacturer across the globe. This can be achieved by producing superior quality products in minimum delivery times through the use of latest machine tools, application of best manufacturing practices and adherence to stringent quality standards. Gajra believes in total customer satisfaction through open communication, quality up-gradation and continuous training, the practice of which will lead it to being recognized as a World Class Gear Manufacturer.

History
Transmission and Differential Gears, Gearboxes - Gajra is the leading automotive gear brand in India, and one of the largest exporters of automobile gears (a range of over 1000 gears) Gajra Gears Limited, Gearboxes, Manual, Automatic, Planetary assembly, Automobile Automotive GEARS, Heavy duty, light duty Trucks, Gearbox assemblies, Propeller Shafts, Quantam Laser Marking Machine, GG Automotive, Spline Shafts & Axles, Planetary Assemblies, 3F Sortainer, Crankshafts, Gajra-Costello Gearbox, Cam Shafts, pitman, Steering Worms etc. The Gajra Group made its beginnings in 1950 with the formation of Elve Corporation. Originally trading in diesel engines and spares it then moved on to making Gears in 1962 with the set up of Gajra Gears. After establishing a name in automotive gears the group further added to its capabilities by setting up Gajra Differential Gears in 1991. With a modest beginning the group has over the years expanded its product range. The Gajra Group now offers transmission and differential gears, cutting tools and toolings (jigs, fixtures) that serve the purpose of manufacturing these gears, material handling pallets for the safe movement of these goods and machined castings and assemblies. What drives this growth at Gajra is commitment to top quality by following good manufacturing practices and providing outstanding customer service.

Group Strengths
Strong Brand Image Latest Technology Machines Strong Product Development & Reverse Engineering Capabilities 50% of Revenues from Exports Over 25% annual growth in OEM business In house cutting tool & fixture mfg. Over 40 years experience in gear mfg. Highly skilled manpower Over 1000 products mfg. Exports mainly in DIN 6-8 Continuous training & improvement Supplier Upgradation - ISO-9000, Better Manufacturing Practices Best Manufacturing Practices - Six Sigma, TPM, TQM

GEAR
A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit torque. Two or more gears working in tandem are called a transmission and can produce a mechanical advantage through a gear ratio and thus may be considered a simple machine. Geared devices can change the speed, torque, and direction of a power source. The most common situation is for a gear to mesh with another gear, however a gear can also mesh a non-rotating toothed part, called a rack, thereby producing translation instead of rotation. The gears in a transmission are analogous to the wheels in a pulley. An advantage of gears is that the teeth of a gear prevent slipping. When two gears of unequal number of teeth are combined a mechanical advantage is produced, with both the rotational speeds and the torques of the two gears differing in a simple relationship. n transmissions which offer multiple gear ratios, such as bicycles and cars, the term gear, as in first gear, refers to a gear ratio rather than an actual physical gear. The term is used to describe similar devices even when gear ratio is continuous rather than discrete, or when the device does not actually contain any gears, as in a continuously variable transmission.

Gear Nomenclature:-

Rotational frequency, n Angular Frequency, Number of teeth, N Gear, wheel Pinion

Measured in rotation over time, such as RPM. Measured in radian per second. rad/second

How many teeth a gear has, an integer. In the case of worms, it is the number of thread starts that the worm has. The larger of two interacting gears or a gear on its own. The smaller of two interacting gears. Path followed by the point of contact between two meshing gear teeth. Line along which the force between two meshing gear teeth is directed. It has the same direction as the force vector. In general, the line of action changes from moment to moment during the period of engagement of a pair of teeth. For involute gear, however, the tooth-totooth force is always directed along the same linethat is, the line of action is constant. This implies that for involute gears the path of contact is also a straight line, coincident with the line of actionas is indeed the case. Axis of revolution of the gear; center line of the shaft. Point where the line of action crosses a line joining the two gear axes. Circle centered on and perpendicular to the axis, and passing through the pitch point. A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined. A predefined diametral position on the gear where the circular tooth thickness, pressure angle and helix angles are defined. The standard pitch diameter is a basic dimension and cannot be measured, but is a location where other measurements are made. Its value is based on the number of teeth, the normal module (or normal diametral pitch), and the helix angle. It is calculated as: in metric units or in imperial units.

Path of contact

Line of action, pressure line

Axis

Pitch point, p

Pitch circle, pitch line

Pitch diameter, d

Module, m

Operating pitch diameters

A scaling factor used in metric gears with units in millimeters whose effect is to enlarge the gear tooth size as the module increases and reduce the size as the module decreases. Module can be defined in the normal (mn), the transverse (mt), or the axial planes (ma) depending on the design approach employed and the type of gear being designed.Module is typically an input value into the gear design and is seldom calculated. Diameters determined from the number of teeth and the center distance at which gears operate. Example for pinion:

Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial direction. More generally, the surface formed by the sum of all the pitch circles as one moves along the axis. For bevel gears it is a cone. Angle with vertex at the gear center, one leg on the point where mating teeth first make contact, the other leg on the point where they disengage. Segment of a pitch circle subtended by the angle of action. The complement of the angle between the direction that the teeth exert force on each other, and the line joining the centers of the two gears. For involute gears, the teeth always exert force along the line of action, which, for involute gears, is a straight line; and thus, for involute gears, the pressure angle is constant. Diameter of the gear, measured from the tops of the teeth. Diameter of the gear, measured at the base of the tooth. Radial distance from the pitch surface to the outermost point of the tooth. Radial distance from the depth of the tooth trough to the pitch surface.

Angle of action Arc of action

Pressure angle,

Outside diameter, Root diameter Addendum, a Dedendum, b

Whole depth, Clearance

The distance from the top of the tooth to the root; it is equal to addendum plus dedendum or to working depth plus clearance. Distance between the root circle of a gear and the addendum circle of its mate. Depth of engagement of two gears, that is, the sum of their operating addendums. Distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the pitch circle. Ratio of the number of teeth to the pitch diameter. Could be measured in teeth per inch or teeth per centimeter. In involute gears, where the tooth profile is the involute of the base circle. The radius of the base circle is somewhat smaller than that of the pitch circle. In involute gears, distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the base circle. Contact between teeth other than at the intended parts of their surfaces. A set of gears, any of which will mate properly with any other.

Working depth

Circular pitch, p Diametral pitch, Base circle

Base pitch, normal pitch, Interference

Interchangeable set

Tooth contact nomenclature

CONTACT LINE

LINE OF ACTION

PLANE OF ACTION

LINES OF CONTACT

LENGTH OF ACTION

ZONE OF ACTION

FACE ADVANCE

PATH OF ACTION

LIMIT DIAMETER

ARC OF ACTION

Tooth thickness nomenclature

TOOTH THICKNESS

CHORDAL THICKNESS

THICKNESS RELATIONSHIPS

LONG & SHORT ADDENDUM TEETH

SPAN MEASUREMENT

TOOTH THICKNESS MEASUREMENT OVER PINS

Pitch nomenclature

TOOTH PITCH

P RINCIPLE PITCHES

PITCH

BASE PITCH RELATIONSHIPS

Gajra Gears manufactures the following types of gears:-

Planetary Assemblies

Engine Gears & Oil Pump Gears

Automatic Transmission Parts

Gear Box Assemblies

Spline Shafts and Axles

Housings

Castings

Gajra Gears also manufactures the following cutters:-

Gear Shape Cutters Gear Hobs

Master Gears Gear Shaving Cutters Full Form Guages

Profile Milling Cutters

Surface Broaches

Tooth Chamfering Cutters

Hypoid Face Mill Cutters (Roughing Variety)

WMW Straight Bevel Generating Blades

Cutters suitable for Conflex Machines 9 and 15 Dia.

Taper Forming Tools (Swaging Cutters)

Latest Technology

M & M Gear Analyzer Used for CNC gear checking, can also check cutting tools, bevel gears and index plates. Latest machines such as M & M Gear Analyzer and the coordinate Measurement Machine along with CAD/CAM and Pro-E Systems are used at Gajra Gears. The quality control department at Gajra Gears boasts sophisticated machines such as the M & M Gear Analyzer Machine and the LK Integra Coordinate Measuring Machine. In addition the department is equipped with the facility of a STANDARDS ROOM where calibration of variable measuring instruments is carries out with studies for Bias, Linearlity and Stability.

LK Integra- Provides measuring solutions for a broad range of products Gajra Gears uses the best manufacturing practices like TPM, TQM and six sigma and also continual training so as to achieve its standards of world class manufacturing.

Process Flow Chart For Manufacturing the Gears:The industry order Forged material from Hind Forge

Measurement Inspection

Normalization at 975 C for increasing hardness

Rough Turning and then finish Turning

Broaching (for providing internal slots)

Grinding of Job (Super finishing Operation)

Teeth Cutting (by Hobbing Machine)

Heat Treatment (for quenching & carburizing)

Honning/Buffing/Lapping

Final Quality Inspection

Finished Product

Ready for Dispatch

Transmission Gears - Upto 400 mm in diameter Spline Shafts and Axles - Upto 700 mm in length Engine Gears, Oil Pump Gears Automatic Transmission Parts Gear Box Assemblies Planetary Assemblies Housings and Castings

The Cutting Tool Division

Gear Hobs Gear Shaper Cutters Gear Shaving Cutters Master Gears Full Form Gauges Tooth Chamfering Cutters Profile Milling Cutters Surface Broaches Hypoid Face Mill Cutters (Roughing Variety) WMW Straight Bevel Generating Blades Cutters Suitable for Coniflex Machines - 9" and 15" Dia. Taper Forming Tools (Swaging Cutters)

Material Handling Division

Gajra-3F Sortainer

Gajra Product Division(GPD)

Crankshafts Axle Shafts Steering Worms Synchronizing Rings Flywheel Ring Gears

Gajra Product Division(GPD) contd.

Cylinder Heads Can Shafts Pitman Arms Propeller Shafts and Components Differential Cages Water Pump Assemblies Flywheel Gear Assemblies

Material Handling Division

Gajra-3F Sortainer

Gajra Product Division(GPD)

Crankshafts Axle Shafts Steering Worms Synchronizing Rings Flywheel Ring Gears Cylinder Heads Can Shafts Pitman Arms Propeller Shafts and Components Differential Cages Water Pump Assemblies Flywheel Gear Assemblies

Gajra Differential Gears

Spiral and Hypoid Gears (Crown Wheel and Pinions) Range Module Outside Diameter Straight Bevel Gears Range Module Outside Diameter 1.5 mm to 10 Module 30 mm to 300 mm 2.5 mm to 12 Module 100 mm to 500 mm

Curvic Couplings and Face Clutches Range Outside Diameter Spider Kit Assemblies 30 mm to 300 mm

CERTIFICATION
The practice of world class manufacturing with a commitment to quality by adherence to stringent standards has earned Gajra Gears the following certifications: ISO/TS 16949:2002 ISO 14001:2004 OHSAS 18001:1999

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