INDUSTRIAL GEAR BOX.PPT

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FLENDER LIMITED VOCATIONAL TRAINING AT PRESENTED BY ABHISHEK MAITY DEPT. OF MECHANICAL ENGINEERING MALLABHUM INSTITUTE OF TECHNOLOGY , BISHNUPUR , BANKURA WEST BENGAL Roll Number:071580107038 Duration: 18.06.09-26.07.09

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QUALITY POLICY OF FLENDER LTD. Flender limited is committed to provide total customer satisfaction through quality leadership in all products related services according to the latest state of technology at competitive price and on time delivery . The quality product established by Flender Limited will ensure quality in design, development, production, installation and servicing to meet customer’s requirement as per international standards

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PRODUCTS GEAR:- BEVEL HELICAL SPUR WORM WORM GEAR HELICAL GEAR SPUR GEAR BEVEL GEAR SHAFT PINION HOUSING

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TURNOVER The monthly turnover of Flender India Kharagpur works is about 7-9 crore rupees. The annual turnover of Flender Group in the last year was more than 1.2 billion euro. HUMAN RESOURCE At present Flender India's Kharagpur works has a work force of 265 employees out of which 195 are workmen and 70 officers. It has four sales region with sales offices at Kolkata, Delhi, Mumbai, Chennai

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TURNING MACHINE The work piece is rotated into a longitudinally fed, single point cutting tool. Turning is the process of machining external cylindrical and conical surfaces. It is usually performed on a lathe.

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HOBBING MACHINE Hobbing is generation process consisting of rotating and advancing a fluted worm cutter past a revolving blank. In this process all movements are rotary, there being no reciprocating movements In the actual cutting process the gear blank and the cutter, rotates together as if in mesh. The ratio of the speed of rotation of the rotation of the hob cutter and the gear blank depends on the number of teeth on the gear and whether the hob is single threaded or multi-threaded.

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BORING MACHINE Boring is the process of enlarging holes, with boring tools, which have been originated by some other manner in work piece. In boring, as in drilling either the work piece or the tool may be rotated and rather work or the tool may be feed motion

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RADIAL DRILLING MACHINE Radial drilling machines have a large, heavy, round, vertical column supported on a large base. The column supports a radial arm that can be raised and lowered by power and over the base. The spindle head is mounted on the radial arm. It cam be moved horizontally to any desired position on the arm. Thus the spindle can quickly be properly positioned for drilling holes at any desired point in a large work piece mounted either in the base of the machine or even sitting on the floor.

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VERTICAL TURRET LATHE MACHINE The machine equipped with both removable chuck jaws and T-slots for clamping the work. The saddle carries five sided turrets. In this machine tool is fixed and the job is rotates on the bed Usually, each motion of successive tool can be controlled by means of stop so that duplicate work piece can be machined with one tooling setup.

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GRINDING MACHINE CYLINDRICAL GRINDING MACHINE SURFACE GRINDING MACHINE

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FLANK GRINDING MACHANE Flank grinding is a different and specialized process as to normal grinding. It is a technique where the flanks of the gears ground after heat treatment in order to impart hardness and improve longevity. Case hardened gears are flank grounded by advanced CNC flank grinding machines. Soft gears are manually flank grounded by using hand held grinding wheels. It is used to sharp the teeth. The pressure angle of the cutter is 20º .

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HEAT TREATMENT SHOP In every gear manufacturing organization there must be a heat treatment plant in order to make teeth harder by getting beam strength. In Flender, there are three heat treatment furnaces, comprising of two carburizing and one tempering furnace. There are other arrangement also, like quenching tank, tempering tank, shot blasting machine, hardness testing machine, etc. operation like carburizing, hardening, tempering and shot blasting etc. are done here. SURFACE TREATMENT OR CASE HARDENING:- Carburizing Nitriding Cyaniding Flame hardening Induction hardening In Flender kharagpur, only carburizing is used for case hardening.

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CARBURIZING Carburizing is the process of adding carbon to the surface. This diffusion will only work to transfer the carbon atoms into steel. Fe + 2CO→ Fe(C) + CO 2 The method used for carburizing are:- Pack carburizing Gas carburizing Liquid carburizing In Flender Kharagpur , gas carburizing method is applying. GAS CARBURIZING Carbon monoxide (CO) gas is supplied to a heated furnace Also, the carburized parts have thin outer layer of high carbon . There are two reasons why it is desirable to avoid this hyper eutectoid layer. If the heated piece is cooled slowly from the carburizing temperature, a pro-eutectoid cementite network will from in the grain boundaries in subsequent hardening. The hyper eutectoid surface carbon content will increase the amount of retained austenite.

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STEP INVOLVED IN HEAT TREATMENT:- grinding champer anti carburising pre-heating of furnace charge carrier arrengement charge and carburizing of charge quenching tempering center grinding straightening of pinion shot bla sting

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TESTING DEPARTMENT Dimensional testing(manual) Hardness testing(rockwell hardness tester) UTS tester Ultrasonic testing Chemical testing Surface finish testing Helix angle checking Die penetration test Vibration/noise/temperature monitoring Gear tooth hardness testing ASSEMBLY SHOP After completed all the machining operation the job sent the assembly shop for assemble. The shaft, pinion, gears are fitted in a gear box. After assembled a gear box they test the fuel system of the job, working capacity, noise and many kind of things. If there are any faults in the gear box they send it again the machining shop for machining. If there is okay then it sends to the purchase department.

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CONCLUSION In Flender I had learned many basic fundamentals of the gear production techniques. Here I have a basic idea of converting a piece of iron to a fully-fleged working gear. Flender mainly produces industrial gear boxes; its customer includes cement factories, steel plants, sugar companies etc. it has a great turnover of about a billion per month. The discipline and the infrastructure explain the company stature in one look. It is worlds one of the leading gear box production plant. Its employees give it a great name with their production skill and hard work. Here it was great for us a s a trainee because not only it offered us to see and learn a great variety of gear box production techniques, but also given us amply support whenever we couldn’t understand any of the techniques.

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Summer Training Seminar – 2009 THANKING YOU ABHISHEK MAITY 3 RD YEAR MECHANICAL ENGINEERING DEPARTMENT