1. Implementation design for inspection
of O-rings
Under Guidance of
Mr. SUFIAN JALILI
MANAGER (QA)
TML DRIVELINES
LIMITED
Under Advisor of
Dr. B.KONDA REDDY
ASST. PROFESSOR
RGUKT
A summer intern project by
S. KESAVULU R101276

2. Gear box assembly process block diagram
 Problem statement: Leakage due to O rings
 Objective: Design, Manufacturing a Gauge
 Observation: Gear box assembly line there are some leakage problems due to O
rings defects and improper fitment

3. 9 Speed Synchromesh G1150 Gear box
Features of G1150
 Designed for higher reliability - Profile Ground Gears
 Five planet range gearing design for higher capacity
rating
 Weight without oil(kg): 220
 Speedo sensor: std magnetic pick up
 Application: Truck
Problems Facing due to O-Rings in Gear box assembly: Proper fitment, Missing of O
ring, Dust on O ring, might be cut , fitting of elongation or compressed O ring

4.  Description of O-Ring
• Mechanical gasket in the shape of a torus
• designed to be seated in a groove and compressed during assembly between
two or more parts, creating sealant the interface
• Relative motion between the parts and the O-ring
• They can seal thousands of pressure.
 Manufacturing methods: Extrusion, Injection
 O ring Material Viton: Synthetic rubber
 Shore hardness: Testing of hardness
 Sizes
 Surface finish
 Functions and Applications of O rings
• Contact stresses increases by increasing
pressure
• It has point contact between o ring and
sealing faces, allows high pressure, stress
without exceeding the yield stress
 O rings are not in exact dimensions, their size
should be in specified tolerance zone

5. Quality standards: Check the condition of O ring, proper fitment
Inspection Methods of O rings
 Visual examination and inspection steps
Fig: Cross Section of O ring
Table: TML Drivelines ltd mainly used O-ring sizes
O RING PART NO CS mm ID mm
271526207704 1.8 9.3
271526207709 2.65 12.37
271526207707 1.8 17.17
271526207703 2.65 20.3
271526207705 2.65 21.69
271526407702 3.55 60
271526207702 5.3 66.04
271526207706 3.53 66.21
271526407701 3.53 72.62
271526207708 1.8 82.27O-Rings used in Gear box Assembly
• O-ring can be inserting into the planet carrier spacer assembly
• Assembly of rear housing
• assembly of piston cover.
• Inlet pump housing (IPH),Oil pump plate, Oil gallery hole

6.  Design of Taper Mandrel
For sizes of ID are 9.3mm and 12.37mm.
After considering the tolerance, tolerance is +-0.2 in the range of 6-30mm of ID.
For ID of 9.3mm:
Maximum limit is – 9.3+0.2 = 9.5
Minimum limit is – 9.3-0.2 = 9.1
For ID of 12.37mm:
Maximum limit is – 12.37+0.2 = 12.57
Minimum limit is – 12.37-0.2 = 12.17

7.  Conclusion
 Taper mandrel gauges are exclusive for given 10 different sizes of O rings
 This taper mandrel gauges measure actual dimension of O ring within tolerance limits
 quick results with the specified tolerances
 Time involved in for inspection is reduced
Laser Marking
• Clearly visible, permanently marked, HD marking, Durability
• Precise beam positioning and a beam highly localized energy transfer to the work
piece

9. Tata motors
TML
Drivelines
Axels and
Transmissions
Tata Motors mission statement
 Technologies & equipment for machine shop, heat treatment, assembly, forge, laboratories and
ERC Proto shop

10. Gauge and Gauge design
 In mass production instead of measuring actual dimension of each part the conformance of the part with
tolerance specification can be checked by Gauges.
 whether the inspected part has been made with the specified limits
 Differ from measuring instruments they are specially made for some particular component, which is
sufficiently large quantities
 quick results with the specified tolerances
 Time involved in for inspection is reduced
Limits and Tolerances:
 Dimension of the manufactured part can only be made to lie between two limits, maximum and minimum
 The high limit (upper limit) for that dimension is the largest size permitted and the low limit is the smallest
size permitted for the dimension.
 The difference between the upper limit and lower limit of a dimension is “Tolerance Zone”
 Accuracy and Perfectness

11.  About TML Drivelines Company profile
 Machining process involved in gear box
 Objective of project
 Introduction about gauge and design
 Procedure(Including O rings)
 Design of Taper Mandrels
 Laser Marking
 Conclusion

12. WCQ
Built in Quality
Don’t accept, build,
ship a defect
Create Customers
in Enthusiasm
Vision, Culture,
Goal