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Industrial Training Report at GNA Duraparts
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Tags: Duraparts, Report, Training, Industrial, Industrial Training Report at GNA
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01-09-2014, 10:47 AM
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Industrial Training Report at GNA Duraparts

t is my esteem privilege, to express deep sense of
gratitude and indebtedness to my major advisors,
Mr. Balbir Singh {personnel department officer} &

Mr. P S Nanda (Manager of the Unit) GNA
Duraparts {GNA auto parts}, Mehtiana for their
expert and inspiring guidance, constructive
criticism and constant encouragement during the
course of this practical industrial training. I am
very thankful to my contact persons i.e. incharges
of the various shops/departments and personnel
department officers who gave me such a use full
guidance. I would be failing in my duties if I do
not thank Mr.Gurdeep Singh Director, GNA
Duraparts Mehtiana, Who allowed me to
undergo practical industrial training. Thanks are
also due to all staff members of GNA Duraparts
and others who took lots of interest in assisting
me during the training period and in making the
repot a success.
PURPOSE OF INDUSTRIAL TRAINING

It is a well-known fact that theoretical knowledge
is totally handicap without the practical approach
to the thing. Main purpose of the industrial
training is to expose the trainees with practical
experience of actual industrial conditions in which
they will require to work in future and make them
aware of the difference between the environment
of industrial and college or homes. Thus the aim of
the industrial training is to understand the layout
of the industry, dealings with the various
operations going in it and makes trainees to learn
from the experiences of the professional Managers
and skilled workmen with whom they are placed
for training who have to work together with
cooperation to achieve the common goal of the
industry. This type of training gives chance for
future advancement, thus giving trainees chance
for specialization in particular fields. In industry,
we perform the work, which we have studied in
our theory portions. We get an extra knowledge
by working in an industry and we also came to
know the problems to be faced in future. This type
of training gives chance for further advancements.
Thus, it gives the trainees a chance for
specialization in particular fields. INTRODUCTION
TO THE UNIT The existence of GNA came into
being in 1946, in a small village called Bundala in
District Jalandhar of Punjab. GNA has made its
presence prominent not only in India but also
across the world. Today, more than 6000 families
are proud to be associated with this giant colossal
tree that bloomed from a seedling sown 62 years
ago. Founded with a modest beginning by Late Mr.
Amar Singh Ji and nourished by his sons Mr.
Rachhpal Singh and Mr. Gursaran Singh, with the
artistic creativity that was gifted to the next
generation by tradition, GNA is now boosted and
taken care by the third generation Mr. Jasvinder
Singh, Mr. Maninder Singh, Mr. Ranbir Singh and
Mr. Gurdeep Singh. Today GNA group has created
an important place for itself in Indian as well as
Global Automotive Industry. GNA group is on a
fast moving track towards growth and
globalization. The company has a large customer
base covering different sectors of the automotive
industry with diversified product range. Along with
this the company shows steady growth profile
even during the time when there is demand
fluctuations in the automotive sector. GNA is an
Original Equipment supplier to various Automobile
Majors besides having a strong presence in the
replacement market.GNA has been accredited with
ISO 9002 and QS 9000 certifications for its quality
systems holds a reliable name in the world of
automotive components. Quality Management at
GNA is a timeless concept wherein, changes in
customer expectations are a driving force to go
beyond conformance to standards. GNAs quality
assurance is equipped with the finest equipment
ranging from metallurgical microscope to mobile
spectrometer, ultrasonic flow detector, micro
hardness testers, surface roughness testers,
profile projectors and involutes profile testers.
GNA sincerely believes in technology up-gradation
for keeping a competitive edge. Indeed, this
explains the continuous replacement of
conventional manufacturing equipment with
modernized transfer lines resulting in increased
productivity and efficiency at low cost. GNAs core
competency lies in its strong knowledge base of
engineering and over 59 years of experience in
manufacturing. GNA has come a long way yet
journey toward excellence is never ending Sri.
Amar Singh Ji made a modest beginning with an
atta-chakki {Flour mill. Late Sardar Amar Singh
established a small unit for the manufacture of
axles under the name of Nirankar Auto Engg.
works in the late 1946. Through the last 62 years
the company has grown in leaps and bounds and
established itself as a major source of vehicle
pates in India as well as in world. Exports market
of GNA range of products have a wide spectra of
applications in heavy, medium and high
commercial vehicles i.e. passenger cars, jeeps,
tractors, trucks etc. GNA group is today spread
over area of 3, 50,000 sq.mts. Employing a total
man power of about 2000 personnel with a turn
over of 29.78 million US $ coming from all units.
Valued customers of G.N.A DIVISIONS Developing
on the bases of Quality, GNA has come a long way
since its beginning (more than fifty years ago)
with an annual turnover nearly Rs200 Crores per
annum coming from four divisions GNA Axles Ltd,
GNA Duraparts, GNA Udyog Ltd. The following
data gives details of GNAs different plants:
DIVISION PLACE COVERED AREA (sqr meters)
PRODUCTS INSTALLED CAPACITY GNA Axles Ltd
GNA Duraparts GNA Udyog Ltd Mehtiana Mehtiana
Bundala 2400 1550 2020 Rear axle shafts,
Hydraulic lift shafts, Powers take of shafts. Super,
bevel & Pinions Propeller shafts assembly, Inter
drive shaft assembly, Steering components
500,000 pcs 100,000 pcs 100,000 pcs 100,000
sets 70,000 pcs 25,000 pcs DEPARTMENTS AND
INCHARGES DEPARTMENTS PERSON INCHARGE 1.
FORGING MR. Anil Kumar 2. GEAR SHOP-1 MR.
Naresh Sabharwal 3. GEAR SHOP-2 MR.B.K.
Thakur 4. HEAT TREATMENT MR.V.L Kadam 5.
ENGG. DEPTT MR. A.K. Jain 6. GEAR SHOP- 4 MR.
J.S. Bhullar 7. GEAR SHOP-3 MR. Anil Kumar
Product range of GNA Duraparts Private Limited
QUALITY: THE HALL MARK OF GNA According to
the management, GNA has always been striving
for achieving the highest possible standards of
quality through the application of most technology
and effective quality control procedures. Equipped
with in house integrated manufacturing facilities,
GNA got ISO 9002 and is heading forwards
getting qs-9000 in a short time. Accounting to S
Gursharan Singh, Managing Director of GNA The
quality policy of GNA is to be the international
market leader in the quality of products it makes
and serve the customer by providing quality
product and services at competitive costs. Our
objective is to provide reliability and customer
satisfaction. Its also GNAs ongoing policy to
create a congenial atmosphere and quality culture
for its employees. ENGINEERING DEPARTMENT
Engineering department is the backbone of the
plants. This is because it accomplishes the tasks
that are vital for the functioning of the other
plants. This department possesses a team of
sound and ingenious engineers, managed by
qualified and experienced technical managers. The
major functions of this department are performed
before the actual production begins. The
department makes the quotations before the order
received and also conducts the feasibility study of
new products. It planes the system (the process
flow, tooling and facilities required inspection
techniques etc) for the development of new
products. Apart from this the department meets
with the routine production requirement like
modification of the existing systems and tooling
methods etc. it also provides documentary support
to the manufacturing and inspection sections in
the form of process instruction sheets and
inspection parameters list etc. a tool room is there
the function of which is to calibrate the inspection
equipments, inspection of various gauges and
tools used after the completion of pre-settled time
period. It also inspect the tools and master
components being manufactured in the tool room.
As stated earlier the functions of the engineering
department are classified into three divisions vi:
New Product Development Routine Production
Requirement and Data Collection Each of the
functions is explained below in detail: NEW
PRODUCT DEVELOPMENT: The following text
provides a technical and vivid flow of the works
that is performed in the engineering department.
The text has been divided into the steps in a
proper sequence, which is actually followed
actually starts from the Marketing department,
which receives the complete technical description
of the products to be manufactured from the
clients. The client may give it in the from of
drawings or they may give an actual sample of the
products If the actual samples are provided then a
detailed inspection of the sample is carried out
and the various dimensions are noted down. From
the inspection data so collected a complete
engineering drawing of the product is made using
CAD systems It is a point worth nothing that the
actual designing of the component is not the work
of the engineering Department of GNA AXLES. It is
rather done by the client himself as per the
requirements of his assembled machinery.
DRAWINGS: Drawing shows the exact size and
shape of the products, its different parts and
subassemblies. These drawing are made on the
standard sized drawing sheets in order to facilitate
their storage. The drawings contain the following
information: Part number (for identification) and
part description. Dimensions set at standard
scale explicitly shown on the drawing.
Tolerances and limits. Material details including
specifications size and finish description. Title
block. Scale and projection. Details of any
inspection requirement Usually the drawings
contain all the necessary technical information
required by the engineering department of the
GNA Duraparts Ltd yet there may be some
information on a separate sheet. These sheets are
rarely required as the axles are in the form of
single component, so all the necessary information
can be supplied on the drawing sheet itself. These
sheets contain: 1. Conditions of testing 2. Heat-
treatment requirement, etc. QUOTATION MAKING:
The quotation making is accomplished in the
following steps: a) Marketing Analysis: The aspect
of the marketing assumes higher proportions for
the complex and assembled products. In case of
GNA DURAPARTS, as single components are
manufactured, the direct engineering involvement
in the marketing section is not necessary. The
marketing departments functions are limited to
the supply of the engineering drawings and other
design specifications to the engineering
department for the feasibility study. However
some technical persons are employed in the
marketing for negotiating with the clients over
technical aspects. Also they assist in giving a nod
to the client for the acceptance of their order as
they know better about the existing facilities. If
the marketing department gives green signal then
the need for high-level feasibility study is felt. b)
Feasibility Study: Once the need for the
product/process planning is established, it is
necessary to determine whether the technology
currently exists to satisfy the need, and if not,
when it will become available. In this instance
technology refers to the technical methodology or
techniques required for achieving a practical
purpose. The feasibility study includes. a. A
detailed need analysis (i.e. definition of system
operations and maintenance support
requirements) b. Identification of alternate
configuration c. Screening and evolution of the
available alternatives and d. Selection of a
preferred approach. The output of the feasibility
study constitutes a proposal covering the technical
characteristics of the preferred system
configuration. This information combined with the
other data is reviewed to determine whether the
work should be further done or it should be
ceased. c) Estimation: GNA DURAPARTS produces
goods on the job order basses so they have to
quote the rates before to receive a job order and
thus they have to compete with several other rival
concerns all over the India. The careful estimation
is thus urgent here. The calculation of the
probable cost of an article before its actual
manufacture is known as estimating. It is fully
technical job and is geared here by this
engineering department. However, the products
here require almost similar operations thus
rendering the job of estimator a little bit easier.
After doing all this, a quotation is made which is
then sent to the client through marketing
department. SAMPLE DEVELOPMENT ORDER: After
this, the sample development order is received
from the client if they feel viable. Then the
engineering department has to accomplish three
major tasks: a) Tool Procurement: -This includes
giving orders to the tool room for making the
Tools then the tools are purchased with the help of
Purchase department. Drawings, specs etc are
supplied to the Purchase section. -The tools hence
obtained are then inspected for the dimensions
and other parameters. -If the tools are found to be
not O.K., they are sent back to the source with the
inspection report and feedback. -If the tooling is
up to the mark then it is sent to the shop. b)
Correspondence with Party: -The correspondence
with the party/client is done through the
marketing department regarding the unavoidable
deviations, if any. With the agreement of the
client, these deviations are incorporated in the
design for the sample development c) Material
Procurement and processing: Two departments
come in to the picture for accomplishing this task.
These are (I) Production Planning and Control
Section (ii) Purchase Section. The purchase
department is supplied with the specifications
according to which it purchases the material. The
PPC department helps to provide the material in
the inventory. . d) Sample Development: The
sample is then developed in the shop in the
batches of 4 or 5 pieces. SENDING TO THE
CLIENT: These samples are sent to the client
through the marketing department, along with the
required reports. The party then sends back the
reaction in the form of feedback if necessary.
PILOT BATCH MAKING: After the checking of the
samples by the party pilot batch is developed. This
is actually the manufacturing of comparatively
large number of pieces. HAND OVER TO THE
PRODUCTION DEPARTMENT: After the
accomplishment of all the above written takes the
charge of the product making is handed-over to
the Production Department. The Production
Department is submitted the following documents:
1. Tooling 2. Tool specifications 3. Production
Drawings 4. Check sheets 5. Order to the store for
the issuance of material from inventory 6. Process
instruction sheets etc. The Production Starts with
the Schedule ROUTINE PRODUCTION
REQUIREMENTS: The engineering department also
completes the routine production requirement of
the factory. This heading includes the functions
given below: Tooling: Both manufacturing tooling
and the inspection tooling are suggested and
provided by the engineering department. Both the
tooling are procured from two sources viz.: a.
Purchase Section: The tools are bought out
against specifications. b. In-house Manufacturing:
Tooling drawing is send to the tool room and tools
are made. After this the tools from both the
sources are checked for the specification in the
Standard Room. Then these are supplied to the
inspection section and the production section.
Documentary Support: This includes the formation
of some necessary documents and supplying them
to the shop for whenever required. The important
documents include: i) Production Drawing ii)
Process Instruction Sheets iii) Stage check sheet
iv) Process flow charts i) Production drawings:
Production drawing provide to the shop supervisor
for ready consultancy and checking of the
dimension of various portions of the shaft
whenever required. ii) Process Instruction Sheets:
Process instruction sheets provide sufficient detail
for all the operating personal that have direct
responsibility for the operation or the process.
Process instruction sheets for the standard
operating procedures are posted on the etc and
are easily accessible to the operators and the
supervisors. iii) Process Flow Chart: Process flow
chart is a schematic representation of the current
or proposed flow. The flow chart helps to analysis
the total process rather than individual steps in
the process. STANDARD ROOM Standard room is
situated in a separate building, yet its functioning
is controlled by the engineering department. The
main reason for the existence of the standards
room is to check the various dimensions of the
master pieces, inspection equipments, gauges etc.
specified by the engineering department. It also
checks the quality of the purchased equipments.
The details of the responsibility of the standards
room can be had from the following text: The
responsibilities of the engineering department can
be divided broadly into two headings: a.
Inspection of Incoming Materials: 1. Receive the
material against drawing number/work order
number. 2. Put some identification number on
tooling. 3. List out the equipments required for
inspection 4. Inspect the tools 5. Make the report
against drawings 6. Get it checked by the
authorized signatory 7. Hand over the inspection
report to the concerned departments. b. Periodic
Calibration: 1. List out the tooling whose
calibration is to be done. 2. Recall the tooling
against the corresponding drawing 3. Inspection
the tooling against the corresponding drawing 4.
Make periodic inspection report 5. Get the reports
checked by the authorized persons 6. If O.K. send
back to the shop after revising calibration status
code 7. Make entries in the corresponding History
Card 8. If the tools are rejected handover to Engg
Department with report Inspection Report: This
report contains the information in the tabulated
format regarding the periodic inspection of some
tool or gauge etc. The format followed in the GNA
Axles Ltd is as followed: GNA Tool Inspection
Report TOOL
DESCRIPITION TOOL
DRAWING NUMBER.
SUPPLIER.
APPLICABLE
TO. SR. NO.
SPECIFIED DIMENSIONS ACTUAL DIMENSIONS
PRODUCTION PLANNING AND CONTROL (P.P.C)
Production of the whole production shops and
serving department is planned and Mentioned by
P.P.C .We start from raw material (steel for axles,
shafts and other components) 1. Steel receiving
and stock maintaining is the job of P.P.C. 2. Steel
purchasing is planned by P.P.C on the behalf of
customer requirement. 3. Planning for steel yard
for blank cutting and forging and then heat
treatment is also mentioned by P.P.C date wise
and according to customer schedule. 4. Daily
production meeting is conducted by P.P.C in which
all production shops have to report and get
planning for day. 5. Daily loading plan for
production shop like hobbing, induction and
machine shop for all models. 6. Daily production
for original equipment customer is maintained by
P.P.C in which production report of W.T.P, product
transportation for dispatch for daily dispatches etc.
7. Stage wise movement of all departments from
steel yard to O.E shop is maintained on the
computer system by P.P.C. 8. System application
and house keeping is additional job for this
department. 9. P.P.C is the main joint of plant
connecting marketing and production and
customer in one chain and drive the system
smooth. FORGING SHOP This shop is the first shop
carry out the manufacturing operations on the raw
material. The raw material is in form of cylindrical
blanks of steel which are unloaded here from the
truck after the necessary inspection by the
chemical laboratory. Forging is a process of giving
required shape to metals or alloys at sufficiently
high temperature. This is the shop where these
blanks acquire the shape similar to that of an axle
shaft or any other shaft (PTO or rock shaft)
excellent forging facilities for the forging are
provided which include both drop forging as well
as up-setting forging. Continuous shaft oil
furnaces are provided to heat the metal stock. The
report about this shop, which follows this text,
explains the capacities and the process description
of the shop in a systematic way. LAYOUT Forging
is the process by which metal is heated and is
shaped by plastic deformation by suitably applying
compressive force. Usually the compressive force
is in the form of hammer blows using a power
hammer or a press. Forging refines the grain
structure and improves physical properties of the
metal. With proper design, the grain flow can be
oriented in the direction of principal stresses
encountered in actual use. Grain flow is the
direction of the pattern that the crystals take
during plastic deformation. Physical properties
(such as strength, ductility and toughness) are
much better in a forging than in the base metal,
which has, crystals randomly oriented. Forgings
are consistent from piece to piece, without any of
the porosity, voids, inclusions and other defects.
Thus, finishing operations such as machining do
not expose voids, because there aren't any. Also
coating operations such as plating or painting are
straightforward due to a good surface, which
needs very little preparation. Forgings yield parts
that have high strength to weight ratio-thus are
often used in the design of aircraft frame
members. A Forged metal can result in the
following Increase length, decrease cross-
section, called drawing out the metal. Decrease
length, increase cross-section, called upsetting the
metal. Change length, change cross-section, by
squeezing in closed impression dies. This results in
favorable grain flow for strong parts PROCESS
FLOW: The forging shop also includes a unit for
the cutting of the incoming raw material (in the
from of standard length blanks) into smaller
specified lengths. After this the heating of the
metal stock is carried out to attain the
temperatures required for the forging operation.
After this the forging is carried out on any one of
the three machines. Sometimes more than two
machines are used for the single shaft. The forged
shafts are then sent to the heat-treatment section
for further treatments. FACILITIES: The forging
shop of GNA axle is equipped with all the modern
facilities required by the operations performed
herein. These facilities include the forging
machines and the furnaces along with material
handing equipments and the shaft cutting
facilities. List of the various machines and
equipments available in the forging and blank
cutting shop is hereby given as under: Horizontal
Bank Saw (3 no.s) Upset Forging Press (2 no.s)
Drop Hammer Continuous Shaft Oil -Fired
Furnace Screw Compressor Over-Head Hoists
Following is the text, which contains the
description of each type of the machines
mentioned above along with the general
specifications and working: Horizontal Band Saw:
Specifications: Number of machines available
3 Model FC-245 Capacity 245 mm diameter
shafts Mfg. By SPM Tools, Ichalkaranji
(Maharashtra) Working: The shaft to be cut is
fitted on the fixture provided on the machine and
switching on the power carries out the cutting
operation. Before it the required length of the
blank is measured and marked. Before using band
saw the tension of the blade is checked with
tension meter. It is calibrated in PSI (Pound per
square Inch). The tension required is different for
different materials to be cut. But usually the
reading should be between 25000 PSI to 30000
PSI. 1. Upset Forging Press: These are the
costliest and heaviest machines at GNA axle. The
production of the whole plant depends upon the
performance of these machines. These machines
have been imported from Russia. Specifications:
Type Horizontal forging press Model IHK
1200 Mfg. By Smeral Works, Berno Russia
Overall Length 6400 mm Width 4420 mm
Height 3830 mm Total Weight 137000 Kg
Total input of Machine 76.1 KW There are two
horizontal forging presses in the forging shop. The
capacity of second machine is also 1200 tones.
Forging Possibilities And Performance of The
Machine: The horizontal forging machine is
designed for the hot upsetting, broaching,
stepping and bending of the forging of black and
non-ferrous metal. According to the
manufacturers manual maximum utilization is
possible in forging shops for serial production of
motor cars, tractors, transport equipments and
upsetting etc. Kinematics Description and
Working: 1200 T means maximum horizontal force
that is applied by the press is 1200 Tonns. The
operative units of the press are powered from
motor mounted on the press frame. By means of
V-belt drive power is transmitted from Pulley to
the flywheel mounted on the auxiliary shaft. The
flywheel is equipped with a friction safety device
to prevent the overloading of shaft. The flywheel is
stopped by the auxiliary brake which is
automatically engaged when the motor is switched
off. On the other end of the shaft a gear is
mounted. It meshes with gears which drive the
crankshaft. The latter through the pitman
reciprocates in the sideway. The crank mechanism
is engaged by a pneumatic clutch which is
controlled by a paddle. The band brake stops the
crankshaft and hence the slide when the
pneumatic clutch is disengaged. The top half of
the is secured to the slide and the bottom half to
the bed which is provided with a double wedge
device for adjusting the die space. 2. Drop
Hammer: The axles having large flange (like:
Mahindra Large, Carraro-644, L & T, New Holland)
are drop forged after their partial upsetting.
Specifications: Type Vertical Drop Hammer
Type Forging Machine Weight of The Die-Block
5 Tonns Input Power 75 H.P Number of
Strokes Required depends upon the size and
shape of the forging The other dimensions and
specifications were not shown by the concerned
foreman due to some legitimate reasons.
Working: Drop hammer having two columns made
of thick steel plates of 35mm V-ways is provided
on the facing sides of the column to guide the ram
connected with upper die block. Stairs are
provided on the side of the hammer for checking
out the functioning and maintenance of the driving
unit. Columns are provided on the heavy cast iron
casting which is foundational in the concrete below
the floor level. Columns are fastened to the heavy
cast iron casting with very large bolts and spring
washers to exert a regular tightening pressure and
to absorb the stock. An anvil is provided between
the two columns and so the upper side of the
heavy base. On the anvil lower die block is
mounted using keys. When the ram falls with high
impact on the lower die block fitted on the anvil
then the shaft placed in the lower die block is
forged to the shape given by the upper die block
(fitted on the ram) and the lower die block.
Foundation of the machines: The foundation is to
be made up of rammed concrete according to the
attached foundation plan. The machines are
mounted on thoroughly hardened concrete to
avoid subsequent setting. 3. Continuous Oil Fired
Furnace: The furnaces serve the need for heating
of the blanks prior to the forging process. The cut
blanks are first place in these furnaces and then
forging is done. Specifications: Number of
furnaces-3 Type- Continuous Shaft Oil Fired
Furnace Fuel Used Rough Furnace Oil
Alternative Fuel load 1200 C (approx.)
Construction and working: Outer body of the
furnace is covered with thick mild steel sheet.
Inside is covered with fire clay refractory bricks.
Upper portion is called gate, which is covered with
bricks from inside. Heating area is divided into two
parts: 1. Pre-heating Zone 2. Heating Zone Pre-
Heating Zone is smaller and at a sufficient
distance from the burner. Burner is provided to
heat up the shall through which hot flame is
exerted. Furnace oil and air from the blower is fed
to the burner. A hood is there to collect smoke
and is exhausted through the chimney. Centrifugal
blowers are drive by electric motors. Airflow can
be controlled by the values at the burner. 4.
Material Handling: There are monorails provided
overhead in the forging shop. These monorails
traverse the way right from the furnaces to the
drop hammer after passing over the up setter. The
manual hoists are provided which can pick up the
load tethered to the hook attached to its hanging
chains. The worked can take the shafts to any
area within the reach of the monorail. The path of
the monorail will be clearly comprehended by
watching the layout of the forging shop. Apart
from these forklifts are also available. These are
used to pick up a lot of axles contained in a rack
made of steel. PROCESSES 1. Blank Cutting: The
blank are purchased from the market through the
purchased department. The latter is submitted the
specifications and the amount of the material to
be purchased. The specifications depend upon the
requirement of the product and the client. The
blanks available in the market possess standard
length, which are quite large than the required
length of the blank to begin with. So these blank
are first cut to the required size by using the
horizontal band saws. 2. Heating: The forging is
done after heating the blanks up to the
appropriate temperature. The temperature
required depends upon the composition of the
steel. The metal is heated above its
recrystalisation temperature. The forging is carried
out at this temperature, when the metal is in the
plastic stage by applying compressive force. The
oil used RFO and freeze at temperature below 80-
degree C. the oil is heated to this temperature and
is kept at the same temperatures. The end of the
shaft to be foraged is placed inside the furnace.
The other end remains out side the furnace. There
are two zones viz. a. Pre-heating Zone b. Heating
Zone A number of blanks can be placed at the
same time in the furnace. First the blanks are
placed in the pre-heating zone while the
previously placed blanks are being heated in the
heating zone. When the blank is the heating zone
acquired sufficient pressure, these are taken to
the forging presses using hoists while the blanks
placed in the pre-heating zone are moved to the
heating zone. 3. Forging: Forging is the process of
giving required shape to the metal or alloys at the
sufficiently high temperature, when the metal is in
the plastic state by applying compressive force. It
eliminates certain defects in the metal. Blowholes,
porosity etc are eliminated. Grains of the metal
are refined. Physical properties are improved due
to improved grain structure. Forging is a relatively
quicker process and save a good amount of time
and expense. There are so many different forging
processes. GNA Axles Ltd uses two methods of
forging viz. a) Upset Forging: This is also called
machine forging. It consists of gripping a heated
bar stock between two dies and striking the
protruding end with another die. The material can
be increased considerably in diameter, and the
other blow can be used to make the metal
conform to the die cavities. This is the prime
requirement in the manufacturing of the axles. In
GNA Axles Ltd four blows in total are used to
make the axle shape on the upsetting machines.
b) Drop Forging: This method is used where a
large number of similar jobs are to be produced.
In this process metal is heated to the plastic stage
and is then hammered to the shape in closed
impression die. Half the impression is cut in one
die and remaining on the other die. One die is
allowed to fall on the other from a height of about
3 meters thus squeezing the metal in between the
dies and converting it to the required shape. 4.
Cooling: The forgings are placed in the steel racks
and are taken out of the shop for air-cooling.
HEAT TREATMENT Forgings produced in forging
shop have developed a considerable amount of
harmful internal stresses. These internal stresses
are harmful as far as the end use of the product is
concerned. These internal stresses are to be
removed now and also the axles are to be
hardened in the Heat Treatment Shop. PROCESS
FLOW: The forgings are brought from the forging
shop and are heat treatment in the suitable
furnace. This includes a number of heat treatment
processes (e.g. normalizing, annealing, hardening
and tempering etc.) All the heat treatment
consists for the sufficient time viz: heating to a
suitable temperature, soaking at that temperature
for the sufficient time and cooling by a suitable
method. After that the heat treatment axles are
checked against the requirement value of
hardness. If the axles are O.K then further
processing is done otherwise reworking is
required. FACILLITIES: The heat treatment shop
of GNA Axles Ltd is equipped with the Facilities to
carry out normalizing, annealing, hardening and
tempering. The shop also has the equipments to
check the hardness obtained during the heat
treatment and hence to decide whether further
processing should be done or not. Following
machine and equipments are installed: 1. Heat
Treatment Furnaces: Specifications: o Type:
Indirect Fired HT Furnace o Total number of
furnace: 7 o Fuel used: Light diesel oil o Air
Source: Electrically driven blowers Working and
construction: The structure of the furnace is a
rectangular parallelepiped whose out side is made
up of steel. The furnace is lined with refractory
bricks from inside. 1. Oil Tank For Quenching:
Specifications: o Oil used: Polymer oil 304 mixed
with water o Minimum Concentration: 9% of oil o
Capacity of tank: 1200 Lts 3. Water Storage Tank
for Quenching: The water level in the tank is such
that the lot of axles should dip property in the
water. 4. Cooling Tower: The tanks are connected
to a cooling tower which is furnished with an
electric pump which keeps the water circulating
during the quenching so that hot water may be
cooled in the tower continuously and fresh may
become available in the tank. 2. B.H.N Testing
Machine: The machine is provided for the
inspection of hardness attained. Note: Tow more
facilities are available in the same shop viz. a)
Shot Blasting Machine b) Ultra Sonic Flaw Detector
These however, will be discussed in the nest
chapter. PROCESS DETAIL Heat Treatment: It is
a process involving the heating and cooling of
metals or alloys in the solid state to produce
certain desired properties (e.g.; hardness,
stiffness and ductility etc.). The axles are an
extremely important and high load-taking
component of the automobile. The axles are to
bear a number of forces some of which include;
weight of the vehicle, driving torque, the impact
forces due to shocks. The load on the axle
becomes more under the Indian conditions of
roads thus increasing the demand for more
reliable and more rigid axels. So if the maximum
service is expected of a steel forging it becomes
necessary to give the forging one or more heat
treatments before it goes to service. Principle of
Heat Treatment: The theory of heat treatment is
based on the principle that an alloy experiences
change in structure when heated above a certain
temperature and it again undergoes a change
when it is again cooed to the rooms temperature.
The cooling rate is an important factor in the
development of shaft and hard structures. All the
heat treatment processes may be considered to be
consist of following three main parts: 1. The
heating of all metal to the predetermined
temperature 2. The soaking at that temperature
unit structure becomes uniform throughout the
mass. 3. The cooling of the metal at some
specified cooling rates to cause the formation of
desired structures within the metal/allow for the
desired purpose. Reason: Axles are heat treated
for the following technical reasons: o Improve
mach inability o Relive internal stresses o Improve
mechanical properties such as hardness and
strength HEAT TREATMENT PROCESS USED: 1.
Annealing: Annealing process consists of heating
the forgings in the furnace to a temperature of
about 750 to 900 c. depending upon the
composition of the steel (to a temperature of
about 30 to 50 C above higher critical point) with
subsequently slow cooling. This result in:
Refinement of grain Removal of internal stresses
Comparative softening of the steel This process
is done prior to the hardening and tempering. 2.
Normalizing: This involves heating the forged
parts in the furnace as in annealing and
subsequent cooling in air. Almost similar results
are produced as in annealing. However mechanical
properties such as tensile strength etc is
perceptibly improved. 3. Hardening of Axles: We
know that the operation of hardening of steel
requires the formation of martensite, which is
obtained following the hardening procedure
described below: a) Heating: Forged axles are
heated above critical point in a box type oil
furnace. b) Sacking: The axle is hold at this
temperature for considerable time as prescribed
by the process instruction sheet. c) Quenching:
Rapid cooling of the soaked axle in water bath for
some time according to the process instruction
sheet. The time and temperature for soaking is
different for the different materials and depends
mainly upon carbon contents. 4. Tempering: When
axle is taken out of the quenching medium it is
hard, brittle and have server unequally distributed
internal stresses besides other unfavorable
characteristics. The axle in this condition is poor
shock resistant and has poor stiffness. Tempering
is done for three main reasons: a) To remove
brittleness b) To retain hardness c) To induce
toughness Following steps are involved in
tempering: a) Heating the gears or axle hardening
in a box type furnace to a temperature between
500-650 C range. b) Holding at this temperature
for some time. c) Slow cooling in air Note:
Tempering of auto parts comes under High
Temperature Tempering which is applied to the
parts subjected to high stresses and impacts. 5.
Carburizing (Case Hardening): Crown Wheel &
Pinions etc are case hardened. This process is just
heating the steel parts to red heat in contract with
some carbonaceous materials such as wood, bone
leather charcoal with compounds such as
carbonates of barium, calcium or sodium which
are termed as energizers. The carbon thus enters
the metal to form a solid solution with iron and
converts the outer surface into high carbon steel.
MACHINE SHOP This is the shop where most of
the work is performed on different machines. In
machine shop, the raw material which had under
gone Forging, Hot Blasting etc. is machined to
final product with the help of different machines.
Different types of machines used in machine shop
are: 1. Lathe machine 6. Hobbing machine 2. High
speed lathe (Churchill) 7. Drilling machine 3.
Straightening machine 8. Tapping machines 4.
Horizontal machining centre 9. CNC lathe
machines 5. Milling machine 10. Grinding machine
SYSTEMATIC WORKING IN MACHINE SHOP TO
GET FINAL PRODUCT (AXLE): Raw material after
Forging and Hot Blasting comes to vendor. The job
of a vendor is to do rough turning of the material
with the help of Churchill, Gobber and lathe
machine. All these lathe machines are copy
turning machines. After this the job is mounted on
straightening machine and is straightened, run out
if any also gets removed on this machine. After
straightening job is mounted on CNC lathe
machines where final turning is done and size
achieved is nearly same to the size of final product
but having some tolerance for grinding. Now the
job is mounted on the Hobbing machine where
various types of splines according to demand are
cut on the job on various machines. After that job
is sent for heat treatment processes like Induction
Hardening and Tempering. These heat treatment
processes are only applied to shaft of axle not to
flange part. After heat treatment processes job is
sent for MPT testing, HRC test. After this job again
comes to machine shop where first of all its
straightening is done. After that Radial Drilling
machine is used drill flange holes of different
diameters. Then these flange holes are tapped
with help of tapping machine. After that these
tapped holes are counter sunken with help of
counter sunk machine. Final work done in machine
shop is grinding. Job is mounted on the Grinding
machine and required sizes of collars and flange
are achieved during grinding. After that axle is
sent for final inspection to quality department.
Where random selection of an axle is done.
Different sizes of axle, Grain size, Grain structure
is checked. Then approved product is sent for
packing. DETAILS OF VARIOUS MACHINES AND
VARIOUS PROCESSES PERFORMED ON THESE
MACHINES LATHE MACHINE : This is one of
oldest machines used in industries to remove
metal from a piece of work to give it a required
shape and size. This is accomplished by holding
the work securely and rigidly on the machine and
then turning it against cutting tool which will
remove metal from the work in form chips. To cut
the material properly the tool should be harder
than the material of the work piece, should be
rigidly held on the machine and should be fed or
progressed in a definite way relative to work.
Lathe machine Processes performed on lathe by a
vendor to prepare an axle are Rough Turning with
copy turning attachment and Facing. Rough
turning is the process of removal of excess
material from work piece in minimum time by
applying high rate of feed and heavy depth of cut.
Principle of Copy turning by copy turning
attachment is to guide the tool in a path which
produces the exact shape as that of specimen on
the job. CNC MACHINES WHAT DOES 'CNC' MEAN
? CNC means Computer Numerical Control. This
means a computer converts the design into
numbers which the computer uses to control the
cutting and shaping of the material. HOW TO USE
A TYPICAL CNC MACHINE 1. The design is loaded
into the computer which is attached to the CNC
machine. The computer changes the design into a
special code (numerical) that controls the way the
CNC cuts and shapes the material. 2. The material
to be shaped is taped on to a block with double
sided tape. This must be done carefully so that it
does not come off the block during machining. 3.
The block is then placed in the vice, inside the
CNC. It must be tightened up carefully. If it is not
secure when the machine starts to cut the
material it can come away from the vice. When
the machine starts working, the vice moves up,
down, right and left according to the design. 4.
The guard is placed in position. It protects the
machine operator in case the material is pulled out
of the vice by the power of the cutter. For safety
reasons, if the guard is not in position the motor
will not start. 5. The CNC is turned on and the
shape is cut from the material. When the cutter
has stopped the shaped material can be removed
from the vice. Total time - for simple designs - 15
minutes. Grinding machine: Grinding is metal
cutting operation performed by means of a
rotating abrasive wheel that acts as a tool against
the work piece. This is used to finish work pieces
which must show a high surface quality, accuracy
of shape and dimensions. Grinding machines
remove the material in little amount, 0.25 to 0.50
mm in most of operation and accuracy in
dimensions is in order of 0.000025 mm. grinding
is basically classified into two groups. 1. Rough
grinding 2. Precision grinding GRINDING PROCESS
CLASSIFICATION OF GRINDING MACHINES
Grinding machines according to the quality of
surface finish are classified as i. 2. Rough grinders
3. Precision grinders In industry the most of work
is done on precisely on precision grinders and CNC
grinding machines. Different precision grinders
used are as 1. Cylindrical grinders (ex.
CENTRELESS GRINDERS) 2. Surface grinders(ex.
HORIZONTAL GRINDERS) 3. Special grinders (ex.
CNC GRINDERS) 4. Internal grinders 5. Tool and
cutter grinders MATERIALS USED FOR GRINDING
WHEEL Now a days use of abrasive belts is
becoming more wide spread in industry. An
abrasive should have properties like purity uniform
physical properties of hardness, toughness and
resistance to fracture. Abrasives may be classified
into two groups: 1. Natural 2. Artificial or
manufactured GRINDING WHEELS The natural
abrasive includes sand stone or solid quartz,
emery, corundum and diamond. Emery and
corundum are natural aluminum oxides artificial
abrasives chiefly include silicon carbide, aluminum
oxide, powdered coke, saw dust. DRESSING AND
TRUING GRINDING WHEEL Dressing removes
loading and breaks away the glazed surface so
that sharp abrasive particles are again presented
to work. This is done with various types of
dressers. A common type of wheel dresser, known
as the star dresser, is shown in figure. It consist of
a number of a hardened steel wheels with on their
periphery. The dresser is held against the face of
revolving wheel and moved across face to dress
the whole surface. Abrasive wheel dressers
operating at high speeds are frequently used to
dress other wheels. They are used where a fair
degree of finish is required on the product. STAR
DRESSER For precision and high finish grinding
and industrial work, small industrial diamonds,
known in trade as bort, are used. The diamond or
group of diamonds is mounted in holder. The
diamond should be kept pointed, since only the
point can be used for cutting. This is done by
holder down at a 15 degree angle and using a new
surface each time the wheel is dressed. A god
supply of coolant should be used while dressing
with a diamond, as over heating of diamond can
cause it to fracture. DIAMOND DRESSERS
TRUING: Truing is the process of changing the
shape of grinding wheel as it becomes worn from
its original shape, owing to break away of the
abrasive and the bond. This is done to make the
wheel true and concentric with bore, or to change
face contour for form grinding. Truing and
dressing are done with same tools but not for
same purpose. DIAMOND DRESSERS CENTRELESS
GRINDING: Centre less grinding is a method of
grinding exterior cylindrical, tapered and formed
surfaces on work pieces that are not held and
rotated on centers. The principal elements of an
external centre less grinder shown are the
grinding wheel, regulating or back up wheel and
work rest. Both the wheels are rotate in same
direction. The work rest is located between the
wheels. The work is placed upon the work rest,
and the latter, together with regulating wheel, is
fed forward, forcing the work against the grinding
wheel. CENTRELESS GRINDING MACHINE The
axial movement of the work past the grinding
wheel is obtained by tilting the regulating wheel at
a slight angle from horizontal, an angular
adjustment of 0 to 8 or 10 degrees is provided in
the machine for this purpose. Centre less grinding
may be done in one of three ways. These are
illustrated as In through grinding, the work is
passed completely through the space between the
grinding wheel and regulating wheel, usually with
guides at both ends. This method is used when
there are no shoulders or other forms to interfere
with passage of work. In infeed grinding, which Is
similar to plunge grinding or form grinding, the
regulating wheel is drawn back so that work piece
may be placed on work rest table. Then it is
moved in o feed the work against the grinding
wheel. This method is used to grind shoulders.
RADIAL DRILLING MACHINE: The radial drilling
machine is intended for drilling medium to large
and heavy work pieces. The machine consists of a
heavy, round, vertical column mounted on large
base. The column supports a radial arm which can
be raised and lowered to accommodate work
pieces of different heights. The arm may be swung
to any position over the work bed. The drill head
containing mechanism for rotating and feeding the
drill is mounted on a radial arm and can be moved
horizontally on guide ways and clamped at any
desired position. These three movements in a
radial machine when combined together permit
the drill to be located at any desired point on a
large work piece for drilling a hole. When several
holes are to be drilled on a large work piece, the
position of arm and drill head is altered so that
drill spindle may be moved from one position to
other after drilling the hole without altering the
setting of work. This versatility allows it to work
on large work pieces. The main parts of Radial
drilling machine are: 1. Base 6. Motor for driving
spindle 2. Column 7. Drill head 3. Radial arm 8.
Drill spindle 4. Motor for elevating the arm 9.
Table 5. Elevating screw As mentioned earlier
these machines are used for drilling straight holes.
After final turning of the axle the work piece is
mounted on this machine and flange holes are
drilled in it with help of this machine. GANG
DRILLING MACHINE: When number of single
spindle drilling machines are placed side by side
on common base and have a common work table,
the machine is known as gang drill machine. In a
gang drill machine four to six spindles can be
mounted side by side. In some machines the drill
spindles are permanently spaced on work table,
and in others position of column may be adjusted
so that space between the spindles may be varied.
The speed and feed are controlled independently.
This type of machine is specially adapted for
production work. A series of operations may be
performed on the work by shifting the work from
one position to other on work table. Moreover
each spindle may be set up properly with different
tools for different operations. Figure of a gang drill
containing 18 spindles is as shown. GANG DRILL
Description of various machines 1. Gear shaper
machine: A gear shaper is a machine tool for
cutting the teeth of internal or external gears. The
name shaper relates to the fact that the cutter
engages the part on the forward stroke and pulls
away from the part on the return stroke, just like
the clapper box on a planer shaper. To cut
external teeth, a different machine called a
hobbing machine can be used. The cutting tool is
also gear shaped having the same pitch as the
gear to be cut. However number of cutting teeth
must be less than that of the gear to be cut for
internal gears. For external gears the number of
teeth on the cutter is limited only by the size of
the shaping machine. The picture of the gear
shaper machine is shown below: Here this picture
shows the shaper machine for internal gear cutting
on a ring. The cutter reciprocates in vertical
direction. This cutter cut gears in forward stroke
and pulls away from the part in backward stroke.
The job as well as is rotating in pre-described
speed. This rotating movement helps the cutter to
cut teeth on the whole inside circumference. 2.
Hobbing machine: A hobbing machine is a special
form of milling machine that cuts gears. It is the
major industrial process for cutting (as opposed to
grinding) spur gears of involute form. The
machine forms the gear via a generating process
by rotating the gear blank and the cutter (called a
hob) at the same time with a fixed gearing ratio
between hob and blank. The hob has a profile
given in cross-section by the fundamental rack for
the gear tooth profile and is in the form of a helix
so that the sides of the teeth on the hob generate
the curve on the gear. The helix has a number of
cuts parallel to the axis to form the cutting teeth
and the profile is suitably relieved to provide
cutting clearance. For a tooth profile which is a
theoretical involute, the fundamental rack is
straight-sided, with sides inclined at the pressure
angle of the tooth form, with flat top and bottom.
The necessary addendum correction to allow the
use of small-numbered pinions can either be
obtained by suitable modification of this rack to a
cycloidal form at the tips, or by hobbing at other
than the theoretical pitch circle diameter. Since
the gear ratio between hob and blank is fixed, the
resulting gear will have the correct pitch on the
pitch circle, but the tooth thickness will not be
equal to the space width. Hobbing is invariably
used to produce throated worm wheels, but it is
not possible to cut all useful tooth profiles in this
way; if any portion of the hob profile is
perpendicular to the axis then it will have no
cutting clearance generated by the usual backing
off process, and it will not cut well. Hob cutter of
hobbing machine. Job and hob cutter in working
position. 3. Gear shaving machine: Gear shaving
machines are used to remove the burr of to make
smooth the surface of the gear teeth after gear
cutting. We know that after gear cutting, the
profile of the gear teethes is not smooth or burr or
irregularities are presents on its surface. So to
make the profile of teethes smooth, we use gear
shaving machines. The axis of the cutter is
inclined at some angle to that of job. Both cutter
and job move in opposite direction. The profile of
the cutter teeth has special shape. These teeth of
cutter mesh with the teeth of the gear. So in this
way, the burr or irregular surface is removed by
these cutters. The picture of gear shaver machine
describes all things. Gear shaver cutter and job. 4.
Surface broach machine: Broaching machines are
special purpose machines. A broaching machine is
widely used as a metal cutting machine used for
surface finishing by pressing a broaching tool on a
work piece surface. A broaching tool acts as a
cutter, which consists of cutting teeth arranged in
a row. A broaching machine works on the principle
of proper offsetting of the work piece and then
performing work on it. The centerline of a work
piece and a broaching tool are aligned to each
other at an offset position of 1. This position
generates a scalloping effect on the work piece
and allows the broaching tool to shear the work
piece. A work piece is kept stationary and the
broaching tool is rotated. In this way, only the
leading edge of the work piece is broached instead
of the full surface. There are many types of
broaching machines.




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