in this u will come to know about various processes involved in manufacturing of gears and also get the experience how to make slide show on training reports.

1. Name – Anurag mishra
)
Govt. Polytechnic - Manesar
Summer Training Report
( On Ring Gear Manufacturing Process )

2. Acknowledgement
Every project big or small is successful largely due to the effort of a number of Wonderful people who
have always given their valuable advice or lent a helping hand. I sincerely appreciate the inspiration,
support and guidance of all those people who have been instrumental in making this project a
success.
I, Anurag, student of Government Polytechnic Manesar (Mechanical Engineering), am extremely
greatful to “Amtek Ring Gear -Gurgaon” for the Confidence bestowed in me and entrusting my project.
At this juncture I feel deeply honoured in expressing my sincere thanks to Mr. Jitender Mishra,
Manager (Engineering & Development) for making the resources available at the right time and
providing valuable insights leading to the successful Completion of my project.
I express my gratitude to the entire Production & QA team, especially
Mr. Vibhu Tyagi, Mr. Jaswant and Mr. Rajiv Dixit for patiently teaching me the office procedures and
guided me through the entire project.
I am very grateful to the HR Department, especially
Mr. Prashant for providing me this opportunity to work in this prestigious Organization.
2

3. Contents
3
About the Company
List of Customers
About The Product
Manufacturing PFD
Process Introduction
IN-House Testing And Checking Facilities

4. ABOUT THE AMTEK GROUP
4
The Amtek Group, headquartered in India, is one of the largest integrated component
manufacturers in India with a strong global presence. It has also become one of the
world’s largest global forging and integrated machining companies. The Group has
operations across Forging, Iron and Aluminium Casting, Machining and Sub-
Assemblies. It has world-class facilities across India, Japan, Thailand, Germany,
Hungary, Italy, Romania, UK, Brazil, Mexico and US. The Amtek Group is comprised of
corporate entities Amtek Auto, JMT Auto, Amtek Global Technologies and other
subsidiaries and associates. With the infrastructure and technology platform developed
over 25 years, the Group is well positioned in the Indian Auto and Non-Auto component
markets.

5. AMTEK GROUP OVERVIEW - SNAPSHOT
5
Founded 1987
Business
Global engineering company with operations across Forging, Iron and
Aluminium Casting, Machining and Sub-Assemblies
Segments Auto and Non- Auto
Manufacturing
Facilities
65 world-class facilities across India, UK, Germany, Hungary, Italy, Russia,
US, Brazil and Mexico
Key Customers
BorgWarner, BMW, Caterpillar, CNH America, Cummins, Fiat, Ford, GM,
Halliburton, Hero, Honda, JCB, JLR, Maruti Suzuki, Tata, Timken and
Volkswagen
Listed
Subsidiaries
Amtek Auto, Amtek India, Ahmednagar Forgings and JMT Auto

6. AMTEK CUSTOMERS
6
2/3
Wheelers
Passenger Cars
Light
Commercial
Vehicle
Heavy
Commercial
Vehicle
Others
Auto Sector
Tractors Railways Others
Non - Auto Sector

7. AMTEK – ARGL ( RING GEAR DIVISION )
7
Highlights
• Significant presence near the OEM’s in India & abroad.
• Units specialised with wide range of Ring Gears for passenger
cars, trucks, buses, tractors & stationary engines
• All units adopt the TQM approach on quality.
Indicative Product Range
•Rolled Ring
• Starter Ring Gear
Ring Gear Ring Gear
•
•O
•n quality.

8. ARGL – MANUFACTURING PROCESS RING GEAR
8
RAW MATERIAL BENDING SLITTING WELDING
HOBBING ID TURNING OD TURNING COLD SIZING
FINAL GEARWASHING HARDENING TEMPERING DE-BURRING &
PUNCHING
NORMALIZING
CHAMFERING

9. ARGL – MANUFACTURING PROCESS ( MACHINING)
9
Ring Blank Shot Blasting Cold Sizing OD Turning
Ind. Hardening Tempering De - burring Ring Gear
Washing Chamfering Hobbing ID Turning

10. 10
RAW MATERIAL
Material SAE 1035 – 1050
SAE 4140
S45C, S48C
XC- 38
BS 970080ZA74
Size (Range) Section: 8 X 11 (min)
28 X 28 (max)

11. 11
BENDING PROCESS
In this Process use Trapezodial section Bar feed in Machine and make straight to
coil form with help of three Rollers.
Given as below.
Note:-
Bar Feeding Position should be as per given sketch because at the time of bending
process material flow direction is Outer Dia to Inner Dia.
Straight Bar convert in Coil form
after this Process

12. 12
SLITTING PROCESS
Make regular spring coil to single part with help of cutter .

13. 13
WELDING PROCESS – Flash Butt Welding
In this Slitted Ring joint with help of
Flash Butt welding machine.
No extra material to be used for
Ring joint .
Main Tool use for Welding is
copper Electrode .

14. 14
NORMALING PROCESS
Normalizing Heat Treatment process is heating steel above the critical temperature, holding for a
period of time long enough for transformation to occur, and air cooling. Normalized heat treatment
establishes a more uniform carbide size and distribution which facilitates later heat treatment
operations and produces a more uniform final product.
Main product characteristics is
1)Hardness (80 to 96 HRB)
1)Gain Size (5 ~ 8)
Product Characteristics :-

15. 15
COLD SIZING PROCESS
After Welding & Normalising process Part Inner Diameter not in regular shape and parts got excess
ovality and Flatness.
In cold sizing process use Hydraulic press and round core bar die to correct the excess part ovality
and flatness.

16. 16
TURNING PROCESS
At this process remove the extra material and maintained the required specification. This process
done with help of CNC Turning Machine.

17. 17
GEAR CUTTING PROCESS
This the Main process and critical in Gear
manufacturing. Cutting gear teeth in turn
blank with help of Hob cutter .
Brief detail given on next slide.

18. 18
GEAR CUTTING PROCESS
Hob Cutter

19. 19
TOOTH CHAMFERING
Gear Tooth Chamfering process used for mainly smooth engaging between Gear and Pinion.
Chamfer cutter use for cutting the chamfer and it’s same as Hob cutter.

20. 20
WASHING PROCESS
During Gear Cutting & Chamfering process many chips , dust & oil stick on the Parts. It is harmful in
Induction Hardening Process, Because all metal particles mix with Quench oil.
Washing process use to clean all sticky particles and Oil.

21. 21
INDUCTION HARDENING PROCESS
This Process use to reduce the wear properties of Gear. It is very critical process.
At Hardening process main parameter is power and time .because Hardness of gear teeth depend
on power and time combination. Hardness checking is a destructive test that’s why this process is
critical . Mainly hardness maintain in Starter Ring Gear is 48 HRC to 55 HRC.

22. 22
TEMPERING PROCESS
This Process use to reduce the excess stress
on material which is occur during Induction
Hardening process.
This is also called “Stress Release Process”
In This process parts kept in closed Furnace
for a particular time & temperature. for
example 220º C & 40 Minutes.
Temperature and Time depend the on the
material grade and Hardness.

23. 23
DE-BURRING & PUNCHING PROCESS
DE-BURRING :-
During the Gear Cutting and chamfering process burr occur on gear face due to cutting feed.
When tool start the cutting action and complete the cycle it always produce burr on second face .
Those burr remove with help of Emery belt.

24. 24
DE-BURRING & PUNCHING PROCESS
PUNCHING :-
Punching process is done for only traceability of parts. This process done with help of Pneumatic Press.
Punching detail give as below.

25. 25
IN-HOUSE TESTING AND CHECKING FACILITIES
Magnetic particle Inspection.
Micro Vickers hardness Testers,
 Shadowgraph,
 Contour tracer
Surface finish tester
Spectrometer
Carbon Sulphur apparatus
UTM,
Tooth Drop ball Testing,
Microscope for Micro Structure Checking,

26. Hofler Lead & Profile testing machine
for gears up to dia of 450mm.
Carl Zeiss CMM with
Gear Analyzing software
IN-HOUSE TESTING AND CHECKING FACILITIES

27. 11/02/16 27
Testing Infrastructure
Standard Room
Metallurgy Lab Testing Instruments Calibration
Hardness Tester
Vickers Rockwell
Hardness Tester
Microscope Dial Calibration
Master
Micrometer
Callibration Master
Height Master
IN-HOUSE TESTING AND CHECKING FACILITIES

28. 28
THANK YOU