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Products made by the Company (David Brown Gear Industries) The main product of David Brown Gear Industries are all kinds of gear, including smaller gear units and huge gear units. 2.Input materials for making these products 1040 steel and EN26 steel are used in producing the gears. 3. A broad classification and listing of various machine tools/machines used in DBGI. Hobber, grinder; gear shaping machine, heat treatment furnace 4. A brief description of the method of manufacture of these products. The main steps of making products are hobbing, shaping, grinding and heat treatment Hobbing uses a hobber with two non-parallel spindles, one mounted with a blank object and the other with the hob. The angle between the hob's spindle and the object's spindle varies, depending on the type of product being produced. The two shafts are rotated at a proportional ratio, which determines the number of teeth on the blank. Note that the previous example only holds true for a single threaded hob; if the hob has multiple z then the speed ratio must be multiplied by the number of threads on the hob. The hob is then fed up into object until the correct tooth depth is obtained. Finally the hob is fed into the object parallel to the blank's axis of rotation. Most of the largest gear units were generated by the hobbing and shaping machines right here at David Brown Gear Industries.

Grinding machines remove material from the work piece by abrasion, which can generate substantial amounts of heat; they therefore incorporate a coolant to cool the work piece so that it does not overheat and go outside its tolerance.
Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material. 5. Any post processing operations such as lapping, finishing, shot blasting etc. used? If yes. Why? These post processing operations such as lapping, finishing, shot blasting are necessary. The products in David Brown Gear Industries are precise. These operations can prevent chips to destroy the surface of products, and make the products look good.

6. Heat treatment of any components carried out? If yes. What method of heat treatment employed? Yes, the methods they employed are normalizing, modulation, surface hardening, nit riding, carburizing. 7. Inspection and quality control of components and products Two types of inspection: Analytical inspection: Tooth to tooth, normal line and change the amount of runout, the base section of deviation, the cumulative pitch error. To do these well, David Brown has measuring tools and inspection instruments. Functional inspection: they used the standard gear to test unknown precision gear. Quality control: High speed gearboxes are designed to comply with API, AGMA, ISO and DIN International Standards. 8. Conclusions All of the processed at David Brown are different ways of achieving the same result, putting precision cut teeth onto gear blanks. Each of gears in David Brown is well produced, strictly accordance with Australia national standards. To fulfil different tasks, they have very clear labour division. Their production and management impressed me deeply. From the visit, we know the specific steps of making gear, from which we saw some manufactory principle. Besides gear manufacture requires paramount accuracy and that in turn means large scale, investment in machinery and machinery maintenance. This will contribute a lot to our understanding of this subject. 9. Your impressions about the visit The Industrial Visit impressed me deeply for three reasons: Firstly the visit is well organized by David Brown staffs, who were also patient and passionate, so that we could have a clear understanding of the factory; Secondly, in the end of the visit, we had the opportunity to have a look at the products they made. These different kinds of gears were exactly excellent, like the works of art. Before that, they must be processed by a lot of steps, each step would contribute to the results of their products, so details determine success or failure; Last but

not least, from David Brown, I can see that wonderful technology and equipments are not enough to contribute the success of the factory, management is equally important. During the visit, I can also realize their advanced management. Above all, we can learn a lot from David Brown and David Browns workers.