A PROJECT REPORT ON
INDUSTRIAL TRAINING
”
“
At G.N.A Axle Ltd, Mehtiana near Hoshiarpur A Project report submitted Sant Baba Bhag Singh Institute of engineering and technology , Jalandhar. In partial fulfillment for the degree of: -
Bachelor of Mechanical Engineering
Supervised by: -
Submitted by: Navdeep singh B.tech/M.E Roll no. 1421221
G.N.A IMT, Phagwara
INTRODUCTION TO THE COMPANY
1.1 Profile of the company:  Company Name Contact Person Address
Established in Covered Area (Sq. Mtr.) Products
GNA Duraparts
Mr. Gurdeep Singh Sihra. V.P.O. Mehtiana, Distt. Hoshiarpur 146001 Punjab (India) Phone: +91-1882-262273 (7 Lines) Fax : +91-1882-262280 Email :
[email protected] 1994 20000 Spur Bevel & Pinions, Bull Gears & Pinion Shafts, Internet Ring Gears, Planet Carrier, Gear Boxes for Agriculture Equipments, Flanges

GNA group is on a fast moving track towards growth and globalization. GNA is a group of auto & transmission component manufacturing companies catering to wide requirements of Automobiles, Automobiles, Tractors, Off-Highway equipment worldwide. worldwide. A professionally professionally managed group Founded by Chairman Sardar Amar Singh ji, whose vision of world class quality manufacturing & global market made GNA most sought after name in its product range. The
company has a large customer base covering different sectors of the automotive industry with a diversified product range. GNA manufactures quality automobile components which meet the highest international standards. The products include Rear Axle Shafts and U. J. Crosses, Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners, Brake S -cam Shafts, P. T. O. Shafts and Forgings for the automobile industry, for use in all types of light, medium and heavy vehicles.
INTRODUCTION
1.1 Profile of the company:  Company Name Contact Person Address
Established in Covered Area (Sq. Mtr.) Products
GNA Duraparts
Mr. Gurdeep Singh Sihra. V.P.O. Mehtiana, Distt. Hoshiarpur 146001 Punjab (India) Phone: +91-1882-262273 (7 Lines) Fax : +91-1882-262280 Email :
[email protected] 1994 20000 Spur Bevel & Pinions, Bull Gears & Pinion Shafts, Internet Ring Gears, Planet Carrier, Gear Boxes for Agriculture Equipments, Flanges

GNA group is on a fast moving track towards growth and globalization. GNA is a group of auto & transmission component manufacturing companies catering to wide requirements of Automobiles, Automobiles, Tractors, Off-Highway equipment worldwide. worldwide. A professionally professionally managed group Founded by Chairman Sardar Amar Singh ji, whose vision of world class quality manufacturing & global market made GNA most sought after name in its product range. The
company has a large customer base covering different sectors of the automotive industry with a diversified product range. GNA manufactures quality automobile components which meet the highest international standards. The products include Rear Axle Shafts and U. J. Crosses, Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners, Brake S -cam Shafts, P. T. O. Shafts and Forgings for the automobile industry, for use in all types of light, medium and heavy vehicles.
INTRODUCTION
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 manufacturer (OEM) of 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, a change in customer expectations is a driving force to go beyond conformance to standards. It is situated at village BINDALA, DISTT.JALANDHAR. It was come into existence in 1946 by S.AMAR SINGH. • •
It is spread in 27 acres. Its annual turnover is 6 0-70 crore. The production run in three shifts 8:00am to 4:00 pm (first shift), 4:00pm to 12:00 midnight (second shift), 12:00 midnight to 8:00 am (third shift).
GNA Udyog (propeller shaft) comes under GNA group. There are two more units also come in it i.e. GNA (axle ltd.), GNA (duraparts). It is one leading industry amongst them which involved in manufacturing of automobile component. The first component produced by them was axle. Growing from strength to strength the GNA brand image has today reached the zenith. High quality auto components, machining in international standard are produced using hi-tech state of art technology developed indigenously. GNA manufacture original equipment for supply to OEMS, spares and export market. The GNA ranges of products have a wide spectrum of application in heavy, medium and light commercial vehicles, passenger cars, jeeps, tractors and trailers. The GNA range of products can be categorized at the macro level as transmission system, hydraulic lift system, hand tool and steel forging.
COMPANY PROFILE
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 55 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 a diversified product range. GNA manufactures quality automobile components which meet the highest international standards. The products include Rear Axle Shafts and U. J. Crosses, Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners, Brake S-cam Shafts, P. T. O. Shafts and Forgings for the automobile industry, for use in all types of light, medium and heavy vehicles. 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. GNA is core competency lies in its strong knowledge base of engineering and over 55 years of experience in manufacturing. GNA has come a long way yet journey toward excellence is never ending. Expanding the vision & keeping pace with the evolving technology GNA has successfully extended its product line to serve the rising needs of the auto component market.
AUTHORIZATION AUTHORIZATION OF THE UNIT
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 a diversified product range. GNA manufactures quality automobile components, which meet the highest international standards. The products include Rear Axle Shafts and U. J. Crosses, Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners, Brake S-cam Shafts, P. T. O. Shafts and Forgings for the automobile industry, for use in all types of light, medium and heavy vehicles.
HEAD OFFICE Mehtiana 146 001, Distt. Hoshiarpur Punjab (India) Click here for a larger view
Phone : +91 (1882) 262273 (7 Lines) Fax : +91 (1882) 262302/262280 Email :
[email protected]
KENTUCKY EXPOSITION CENTRE
60th IAA Show, Hanover, Germany
LOUISVILLE, KENTUCKY, USA.
23-30 September, 2004
Friday, Saturday, Sunday
Hall No.H11 Stand No.F48
September 24-25-26, 2004
at Fairgrounds of Deutsche Messe AG-
STAND NO:4711
Hanover, Germany
CUSTOMERS OF GNA UDYOG
Valued Customers � Prop Shaft Assy & Components •
•
Ashok Leyland Nissan Ashok Leyland Limited (Heavy Commercial Vehicles
•
Asia Motor Works
•
Case New Holland
•
•
•
•
•
Tata Motors Ltd ( Medium & Heavy Commercial Vehicles) Swaraj Mazda Limited (Light Commercial Vehicles) Maruti Udyog Limited ( Passenger Vans/MUV�s) Mahindra & Mahindra Limited New Holland Fiat India Pvt. Ltd.
•
JCB
•
ITL (Tractors)
•
Caterpillar
•
Preet Tractors
•
Action Construction Equipments Limited (Tractor Division)
•
Piaggio Commercial Vehicles
Valued Customers � off Highway Vehicles •
•
Mahindra & Mahindra Limited New Holland Tractors India Pvt.Limited
•
Preet Tractors Limited
•
Indo Farm Tractors Limited
•
International Tractors Limited
Group Customers •
John Deere
•
Renault
•
CLAAS
•
JCB
•
Graziano Transmissions
•
TMA, USA
• • • •
•
Arvin Meritor Case New Holland Carraro Automotive Axles Limited (Tier I Supplier) TAFE (Tractors)
   
GROUP COMPANIES
GNA Udyog Limited 
GNA Axles Limited 
1.4 Products Range-
GNA-IMT 
GNA Duraparts 
Spur, Bevel & Hypoid Gear Bull Gears & Bull Pinion Shafts Internal Ring Gears Sun Gears & Planetary Gear Transmission Shafts Companion Flanges Axles
  
MANUFACTURING FACILITIES •
Forging
•
Heat Treatment and Induction
•
Process Of Pivot Pins
•
Machining
•
Assembly
•
Tool Room
VAR IOUS DEPA R TME NTS IN G NA DURAPARTS
Forg ing s hop
(i) Forg ing I (ii) Forg ing II
Heat treatment cell
Product planning control (P PC )
Metallurg ical lab
E ng ineering cell
C omputer network control (C NC )
Die s hop
MA C HINE S US E D IN VA R IOUS DEPARTMENTS
PR ODUCTS MADE IN G NA G R OUP
G eneral des cription
B rief notes on production procedure of s ome main products
Various departments in GNA Duraparts 1).
FORG ING SHOP : Forging involves heating of a metal stock to a desired temperature; enable it
to acquire sufficient plasticity followed by the operations like hammering, bending & piecering etc. to give it the desired shape. The forging process is very important and has indispensable position among the various manufacturing processes generally adopted in the workshops due to some reasons i.e. it refines the structures of metal, it renders the metal stronger by setting the direction of the grains & it effects considerable saving in time the labour and material as compaired to the production of same by cutting from a solid stock and then shaping it.
Forging department is one of the most important as every production is started from here it self. There are two types of forging sections. The
categorization can be done on the base of the mechanism of the various machinery present i.e. in forging I we can say upsetting forging/closed die forging and similarly in forging II we can say it as drop forging/open die forging. These two sections consist of under mentioned machines:
(i)
Forg ing I:
It consists of following machines:
Horizontal bandsaws having capacity of working upon maximum diameter jobs of 245mm, power3HP or 2.2 KW, efficiency of 82% & RPM of 1430. The diameter of job varies from 75 to 125mm. (ii)
Forging furnace can be gas or oil fired and are widely used for heating the
jobs for hammer forging. They prove quiet economical and facilitate better temperature and atmosphere control. Here in this shop oil fired is mostly used in which furnace oil is used as a fuel. There are brick arrangements provided in these furnaces Forging furnaces having working temperatures of 1123-1200 degree Celsius, mounted with 10hp powered motor & have capacity of work to be done of 1.25 ton/hr. (iii)Up set forging machine here are of two types and can be differentiated with the help of its working load capacity i.e 500 ton and 800 ton. The diameter of the job that can be worked upon these machines are 115 and 150 mm respectively. The power used
for running of these pressure.
machines is pneumatic type i.e. air
(iv)Compressors for producing air pressure for working the pneumatic machines. These are of reciprocating type. The oil used in the is of type AWS 100. he capacity of oil tank is of 10 litres. Working pressure
is of 7kg/cm2g and
hydraulic test pressure is
11.55 kg/cm2g. In forging I two types of products are being made. One is axle. The total production of the axle per day is 650 to 700. similarly
the product made is shaft & the total production per day is 200 to 300.
Forg ing II : There are following machines in this shop: (i)Forging furnaces are used to heat the raw material up to 1100 degree Celsius with the help of rough furnace oil, which is used as fuel. The feed of rough material are given in batch type feed and in continuous way. A pusher is provided to push the rectangular work pieces, which are brought, from the band saws. This pusher is operated by an electric motor. There is a pump to control the amount of oil to the furnace. (ii)Power hammers here are of two types are of two types i.e. capacity wise one is of 6.5 ton and 2.5 ton. These hammers are used to hit on to the die to form several shapes of products e.g. crown etc. These machine are working on the principle of pneumatic type i.e. power used is of air
pressure. Pneumatic hammer is operated by a rotary air compressor of single stage type of two in quantity. Air is compressed to pressure of 7 bars and temperature of 120 degree F. the maximum pressure can be produced up to 20 bar. A foot operated lever controls the air supply and required blows of the hammer is obtained. This hammer is used for forging of ring gear, drive gear, tail pinion, star gear and bevel gears etc. (iii)Power presses are kept in adjacent side of these power hammers so that they can be used for piercing and blanking operations just after hammering. These presses are of mechanical
type and have capacity of 400 and 200 tones. These presses work on the crank mechanism. (iv)Normalizing furnace is used to normalize the product, which is to cover the cracks produced after hammering and other machines. The normalizing temperature is kept at the constant value of 880 to 920 degree Celsius with the help of setting of thermocouple. The type of structure obtained will depend upon thickness of the cross section and rate of cooling. Thin section will give much finer grain than that of thick section. Furnace oil is used as fuel in the normalizing furnace. There are 3 heat zones while this process. For example when material is 20MnCr5 zone I is of 880 degree C, zone II is of 900 degree C & zone III is of 920 degree C. time taken for all these is only 20 minutes. The purposes of normalizing are to produce a uniform structure, grain
refinement, reduce internal stresses, improve mach inability & improve hardness, strength & other mechanical properties.
(v)Short blasting machine is used for removing scaling produced due to past processes. This is done by throwing small size balls on the work material in batch way. This also produces somewhat good surface finish. The common material of metal shorts is malleable iron & cast steel. (vi)Brinell hardness tester is used to know the hardness in brinell scale before sending the product to next procedure. In forging II there are also two main products i.e. crown and bull gear. The total production per shift of these two products are 250
and 300 respectively. The total number of workers in both forging I and forging II are 100.
Forging Furnaces:The furnaces used in the unit are oil-fired furnaces. In these furnaces, first of all from the main tank the supply of oil is provided to the furnace. A pumping unit is provided to all the furnaces used and this pumping unit consists of a heater which heats the oil to a temperature of 90-100 degrees and then the oil is supplied to the furnace. A blower is present which moves the air into the recubature. Its function is to heat the air to a temperature of about 250 degrees ant
then move the air into the furnace. The furnace temperature which is used for forging is 1250-1300 degrees. A regulating valve is present and it is used to regulate the supply of oil and a butterfly valve is present to regulate the supply of air.
Following are its two types:1.
Pus her-type furnace: - In the pusher-type a pushing system is provided which is used to push the work-pieces into the furnace. The pusher mechanism which is used is hydraulic and it is controlled by oil pressure. The temperature inside the furnace is 95-105 degrees and the pressure is 12-15 pound per square inch (psi).
2.
Batch-type furnace: - In the batch-type furnace, a batch of the work pieces is made & that batch of work pieces is heated at the required temperature & afterwards the work pieces are moved one by one to the forging machines.
Working procedure in forging s hop: 1. Material
cutting : - This is the first step which is involved in forging. After
the material is received & inspected it is sent for the material cutting. In material cutting operation the material is cut in accordance with the required dimensions. The material cutting is done on band saw machines which are
fully automatic in operation. After the material cutting is done the material is sent into the forging shop. 1.
Heating: - This is the second step which is involved. In this step the material is heated to the forging temperature in the furnace. The forging temperature is 1250-1300 degrees. The furnaces which are used are oil-fired furnaces & they can be either pusher type or batch type. After the material is heated it is sent to the forging machines. The process of heating the stock can be divided into two stages: -
First stage (Preheating zone): - In this stage the temperature to which the stock is heated is 500-700 degrees. Second stage (Full heating zone): - In this stage the temperature is 1260-1300 degrees. 3.
Forg ing: - In this step the material is forged on either a drop hammer or a forging press or on the up-setter. The type of the machine which is to be used depends upon the shape & size of the component to be forged.
4.
Trimming: - In this operation the excess & unwanted material is removed from the forged component. After forging operation is done then the forged component is passed to the trimming press for the material removal.
1.
Heat treatment: - After the trimming operation is done then the forged component is ready for heat treatment. In this operation the forged
components are placed in trays made of mild steel & are placed in the furnace for a suitable period of time. The heat treatment processes which are done at GNAU are normalizing, hardening & tempering. The type of the heat treatment process which is to be done depends upon the type of the steel. After heating, quenching of the heated components is done in a quenching bath for a suitable period of time. The heat treatment process is done to improve the mechanical properties of steel & to relieve the internal stresses which are set up due to forging. 6.
S hot-blas ting : - This process is done to remove the scales & impurities which are caused during heat treatment. After the heat treatment the components are put in the shot-blasting machine & thus the scales are removed & the components are polished.
7.
Grinding: - This is the final step involved. In this step the unwanted material is removed from the components to provide them a smooth surface finish. The grinding process is done on the grinding machines which comprises of the grinding wheel. After the grinding process is completed the hardness checking of the components is done & afterwards these forged components are sent to the machine shop for further machining.
Meas uring ins truments us ed in forg ing s hop: The measuring instruments which are used in the forging shop are: 1. Vernier caliper 2. Measuring scale
1. Measuring tape 4. External & internal calipers
Temperature meas urement ins truments us ed in forg ing s hop: 1. Thermocouple 2. Optical pyrometer
The thermocouples are located at suitable heating zones inside the furnace & they measure the temperature of the heating zone & this temperature is represented on the digital temperature indicator to the operator.
Furnace oil us ed in forg ing s hop: The furnace oil which is used in the furnaces is the residual furnace oil (RFO). Fuel consumption in the furnaces is 100 liters.
4 ). HE AT TR E ATME NT: Heat treatment is defined as an operation involving heating and cooling of a metal or alloy in a solid state to obtain desirable conditions. There are many causes of the heat treatment to be done to the product to be done. It is
done to cause relief of internal stresses developed during cold working processes. It is done to harden and strengthen materials, improve machine ability, change grain size, improve ductility and toughness, increase heat wear and corrosion resistance of materials & to homogenize the structure.
product to give it required hardness. This is done with the help of following mentioned processes & various machines: I.
Carburizing : Carburizing is a method of introducing carbon into solid iron-base alloys in order to produce a hard case. Carburizing may be pack carburizing, gas carburizing and liquid carburizing. But here only gas carburizing is being done. In this process components are heated at 920 degree Celsius for four hours in an atmosphere of gases of [CO+H2+N2]. The main motive of this process is to diffuse into the outer surface of the
components. It is the process by which the increasing of percentage of carbon is being done to gain good surface hardness. This can be only possible with the help of following apparatus: (i)EOT crane is used to carry the fixtures on which batches of items are carried. This crane has capacity to load 2 ton.
(ii)Washing bay is filled with casting soda in which is the products which are covered with layer of oil & coolants are being washed. This process is being done for 10 to 15 minutes.
(iii)Carburizing furnace is the apparatus used for carburizing process. In this apparatus the temperature is maintained at 920 degree Celsius. In this after washing the crane lifts the fixture of the products and put into this apparatus. This process is carried for long period of 15 to 16 hours. The fluid used in this process is carburizing fluid 440. (iv)Super quenching apparatus is the area where the fixture from the last process is put into. In this process the super quenching oil is the quenching medium. There is heat exchanger arrangement which does not allow the temperature of oil to raise more than 75 degree Celsius. II.
Tempering: Tempering involves heating hardening components below the lower critical temperature i.e. at 180 degree Celsius. In this process this temperature is being hold for about 2 to 2 ½ hours and the cooling is being done open air. At this temperature a hexagonal lose packed carbide begin to form and with the rejection of carbon the crystal structure of martensite changes from tetragonal to body centered cubic characteristic of ferrite. This process is being carried with the help of following apparatus:
(i)Tempering furnace is used for this process in which temperature is being maintained between 200 & 250 degree Celsius. In this furnace the walls
inside are winded with the element which is being heated and there is a motor attached to fan to spread the hot air on the fixture on which the products are being arranged.
Scaling removing: It is being done with the help of short blasting machine. This
III.
process is used to clean the components after heat treatment. The metal slides are thrown on the surface e of the components. The material used as the short balls are malleable
iron, cast iron or cast steel. IV.
Hardness checking: It is being done with the help of Rockwell hardness testing machine. The harness is kept between 58 & 61 Rockwell hardness.
Purpose of Heat treatment: 1. To relieve the internal stresses set-up in the material after hot or cold
working in order to improve the machinability. 2. To improve the mechanical properties like tensile strength, hardness,
ductility, shock resistance etc. 3. To modify the structure of steel. 4. To increase the corrosion & wear resistance.
Furnace specifications:
Type of furnace – Oil fired
Fuel used – Residual Furnace Oil (RFO)
Maximum loading capacity of trays - 150-200 kg at a time
Capacity of hardening furnace – 15 ton
Maximum loading capacity of furnace – 12 trays at a time
Capacity of tempering furnace – 15 ton
Fuel consumption – Approximately 100 liters per day Measuring instruments used in heat treatment: -
1. To check heat treatment furnace temperature, Temperature controller /
Indicator thermocouple are used. 2. To check hardness, BHN Testing Machine / Micro-measure are used. 3. To quench oil temperature checking, temperature indicator is used.
Heat treatment of machi ned components : The first stage of the heat treatment was concerned with the heat treatment of the components after forging. Now in the second stage comes the heat treatment of the components after machining. These heat treatment processes mainly comprises of the case hardening techniques of heat treatment. The case hardening processes which are used in GNAU are: 1. Induction hardening: - The Induction hardening is a surface hardening process
in which the surface layers of the metal are hardened but a relatively soft core is maintained. The induction hardening is achieved by passing a high frequency alternating current through the work-piece which is placed in an inductor coil. The alternating current generates a magnetic field of equal intensity but of reverse polarity. Thus, the current penetrates & the surface of
the piece is hardened but a soft core remains. 2. Carburizing: - Carburizing is the process of saturating the surface layer of steel
with carbon. The main purpose of carburizing is to
obtain a hard & wear-resistant surface on machine parts by the enrichment of the surface layer with carbon. The various machined parts
are
directly
carburized after
getting
machined &
after
carburization they are sent for final grinding. There are various techniques of carburizing like – pack carburizing, gas carburizing & liquid carburizing. At GNAU gas carburizing in the electrical carburizing furnace is done.
Heat treatment equipments: 1. Induction hardening machine (medium – frequency) 2. Carburizing furnace (electrical) 3. Tempering furnace (electrical) 4. Magnetic particle tester (MPT) 5. Hardness Testing machine 6. Grinding machine 7. Gas welding machine
Procedure for Induction hardening : -
1. Machining – After forging the components are sent to the machine shop for the
subsequent machining which is to be done & after machining the components are ready for the case hardening. 2. Induction hardening – After the subsequent machining is done in the machine
shop the components are ready to be induction hardened & the induction hardening is done on the induction hardening machines which are of medium & low frequency. The main tooling of these machines is the induction coil.
1. Hardness testing – After the Induction hardening is completed the hardness
testing of the hardened pieces is done. The hardness tester is used for testing the hardness. 4. Checking case hardness – After hardness testing is done the checking of
the case hardness of the components is done to find the depth of the hardened layer. The micro-measure is used for checking the case hardness. 5. Magnetic particle testing (MPT) – In this step the components are checked for
any cracks which might have been developed during the induction hardening. First of all the components are sprayed with kerosene oil & then they are viewed under the ultrasonic light for finding any crack. If any crack might be present it would be illuminated with green light. 6. Tempering – Tempering is done to remove the brittleness which might have been
developed during heat treatment & thus it restores the ductility of the hardened component. The tempering is done in the tempering furnace which is electrical in its operation.
7. Grinding – Grinding is the final step which is involved. In this step any
unwanted material which is present at the edges is removed & a smooth finish is provided.
5). P R OD UCT PLANNING CONTR OL {PPC} : PPC includes the investigation, co-ordination and it ensures timely production of products through efficient and optimum use of facilities like man, machine, material evaluation of manufacturing capabilities and requirements and money. PPC’s function serves as the brain of the organization. Its objective is to provide a physical system together with a set of operational guidelines to efficiently convert materials, human skills and other inputs into finished products. The highest efficiency in production is obtained by manufacturing the required quality, at the required time by the best and cheapest method. Management employs production planning and control {PPC} to coordinate all manufacturing activities.
Products are manufactured by the transformation of raw materials. Planning looks ahead, anticipates possible difficulties and decide that in advance as how to production and how it can be carried out in best way. A production planning control system has main function to perform some before arrival of raw material and tools and other while the raw material process undergoes processing. The main function of this section is to plan about production of the product. This includes many things such as raw material ordering, processing time management etc. This department calculates the total production time of each product and thinks it advance process working period. The main motive of this department is to reduce the inventory of raw
material. So there fore the planning is done such that the total amount of steel kept in unit is under control. Following mentioned are step by step calculations which are planned for raw material planning by PPC department: 1)
Number of components in (i). Cutting section (ii). Forging (iii). Forging vendor department (iv). Vendor (v). Machine shop
1.
Total
3)
Target of the month(say February)
4)
Steel stock
5)
Peaces that can be made from stock
6)
Due steel
7)
Pieces that can be made from the due steel
8)
Total
9)
Balance for next month(say march)
10)
Weight of piece
11)
Net steel required
From above all steps we can see that the main motive of PPC department in raw material planning is that overhaul process will start 2 months before the need so that forging takes place in 1 st month and rest work in last month. Thus by all this planning the department decides the need of net steel as raw material.
Objectives of PP C: 1. To maintain adequate but not excessive stocks of raw materials, work in
process and of finished goods to meet production requirements and delivery schedules. 2. To coordinate the production activities of different departments. 3. To ensure effective utilization of production facilities. 4. To
prepare production schedules advertisements to meet delivery
schedules. 5. To operate the plant at optimum level of efficiency. 6. To ensure production of right product in right quality at the right time.
Importance of PP C: 1. PPC acts as factory’s nervous system as it regulates all plant operations just as
nervous system regulates muscular movements. 2. PPC acts as an effective instrument for cost control. 3. PPC is helpful in accelerating industrial productivity. 4. PPC rationalizes plant operations. 5. PPC benefits the society.
Functions of PP C: Following are the main functions of PPC:-
1.
Planning: It is necessary to plan things properly for getting best results. Similarly for production planning in advance, it is very necessary that how planning should be done and controlled. It is the department which decides about each element of the job, what should be done, where, how & when? Functions of Planning:
To investigate about the complete details and requirements of the product to be manufactured.
Predetermination of future achievements.
Planning about quality and quantity of material.
Planning the design of the product to be manufactured.
Planning about the sequence of the operations.
Planning about interval transportation.
2.
Routing: Routing may be defined as the selection of path, which each part of the product will follow being transferred from raw material to finished products. Path of the product will also give sequence of the operations to be adopted. In other words routing means determination of most advantageous path to be followed from department to department and machine to machine till raw material gets its final shape. Routing in industry depends upon the nature and the type of industry:
Continuous industry – As such these industries are also automatic. Therefore the problem of routing in these industries is very simple. Once the route is decided in the beginning, generally no further control over the route is needed.
6). ME TA LLUR G ICAL LA B :
This lab’s main purpose is of do inspection f raw material do acceptance or rejection of the material. This also helps to now various contents of material in the made specimen after forging processes. So there fore this department is an essential part of the industry. This lab performs the following functions:
(i)
Macro Etch test in which HCl is being used to clean structure of given metal.
(ii)
Jominy hardenabily test is performed in which we do heating and then end quenching and then check the hardness of the specimen.
(iii)
Step down test is the test in which magnaflux on step down sample is being done.
(iv)
Cracks detection is the test in which magnaflux powder and kerosene mixture is used to clean the surface and the checking of cracks is done in microscope.
(v)
Grain size checking test is a test in which the grain size is being checked with the help of microscope.
(vi)
Microstructure checkup up is being done after normalizing, tempering, hardening, carburizing etc. The main frequently performed work in this lab is estimation of percentage of carbon in the specimen in between the production processes. In this the chips of the material is being produced using the
drilling machine. Then their chips are heated in the furnace with cupric oxide (CuO) in presence of dry oxygen free from carbon dioxide. The reaction took place is as below: C + 2CuO = CO2 + 2Cu Other gases and carbon dioxide are absorved in U tubes containing anhydrous (CaCl2) and solution of K(OH) respectively. The volumes of containers are noted before and after the combustion. These volumes are compaired with the charts and thus percentage of carbon is estimated.
Similarly there are some equipments and apparatus required for performing various tests which are mentioned as in following:
I.
Treatment or experimental zone:
(i)
Combustion table furnace
(ii)
Control unit for carbon apparatus {used to know about carbon content and working temperature kept is 1200 degree Celsius}
(iii)
Strohlein apparatus {used to know carbon content in steel}
(iv)
Weight balancing machine
(v)
Barometer {used to know the atmospheric pressure}
(vi)
Volumetric section {used to check % of Mn, Cr, Ni, Cu, molebedinum,sulphur, phosphorus &vanadium}
(vii)
Fume chamber
(viii)
Distillation plant
(ix)
Microscope
(x)
Drilling machine
(xi)
Phosphating tank
(xii)
Surface grinder
(xiii)
Muffle furnace{temperature ranges from 0 to 1200 degree Celsius}
(xiv)
Jominy apparatus for quenching test
II
S ample preparation zone:
(v)
Polishing machine
(vi)
Belt grinder (vii)
Abrasive machine {used for sample cutting}
7). ENGINEE RING CELL: In this department the main purpose is to make a file/report on the product to be manufactured. First of all the customer send the intimation of the product to the purchase department in which there are many things such as bill of material to be used for manufacturing the product, drawing of the product, tolerances, mechanical properties of the product etc. This file is being brought to the engineering department. The engineering department consists of designers, engineers and drafts men who helps in performing their work in this department. The engineering
department first of draws the product lay out. Then the flowchart of the manufacturing processes are being made. Then in the same serial order the list of costs incurred for manufacturing of the product is being made. This quotation may contain various kind of costs such as cost for raw material, machining, labour, die arrangements etc. So there fore the main function of the engineering department is of preparation of details of manufacturing information of the product to be made.
This all work of engineering department is done for the requirements of good production which are mentioned as following: 1). To ring customer satisfaction that the product will work properly and the price is reasonable. 2). Adequate profit that it should be easy to manufacture with in the available resources and should call for minimum number of operations. According to this department the main part is the drawings of the part. A designer communicates his ideas to the manufacturing section through the medium of drawing. Drawing shows the exact size and shape of he product.
An engineering drawing should contain following information for the manufacturer: 1. Component part number and part description. 2. Dimensions from a common datum face to facilitate setting and ganging. 3. Tolerances and limits allowable.
4. Material details or the specifications. 5. Finishing description.
8). COMPUTE R NETWOR K CONTROL (CNC): CNC shop is equipped with various costly machines, which may be automatic, and computer controlled type. The labour used in this shop is highly skilled type. The list of various machines used in this shop is as following:
Gear hobber made by Churchill Company in England. This machine is of mechanical type and have maximum full load current 15 amps.
Gear hobber made by Lorenz Company having maximum hammering load capacity of 1.5 kg.
Gear hobber made by Lorenz Company having maximum hammering load capacity of 1000 kg.
CNC – 03 made by Frontor 1856 weisser. It is assembled with a monitor of simens. This machine is used for rough turning & facing functions.
CNC – 03 made by Frontor 1856 weisser. It is assembled with a monitor of simens. But this machine is used for final turning, boring, step facing etc.
Horizontal machining center made by Rolland, which is a universal machine. The coolant used is biostable coolant. The machining capacity is 500 L.
Grinder with a tapered wheel made by Fortuna Werke AG.
CNC Turning machine made by Frontor 1856 Weisser.
Vertical CNC machining center made by Hart Ford. The various functions that can be performed are drilling, milling, boring, reaming & tapping. This machine can be worked at higher RPM i.e. 8000 RPM.
Surface broaching machine, which works vertically and is made by Varinelli.
CNC machine used for turning operation and is made by Duplo Standard. The control panel is of sinumerilic.
Then there are 5 CNC machines in line. These all are made by Itala.
CNC drilling machine made by Leadwell.
CNC robodrill made by Hanuc.
12). DIE S HOP:
Die is a cavity in which the hot piece is placed in forging & by the application of force the hot metal is given the required shape. So the die is the exact shape of the original component. Dies are of two types: 1. Rough blocker: - Blocker is the die which has the larger dimensions so that more metal flow is incorporated in first blows.
2. Finisher: - Finisher is the die which has the exact dimensions including tolerances used to give the product during forging whole of metal not flows
in the cavity. Some of it comes out to counter it a hollow portion is incorporated around die & this portion is called gutter. Die is the most important tool for closed die forging. Making a die as per design specifications is most essential work in automobile industry. Die manufacturing is a completely sequential process, due to this there is a separate die manufacturing section is
provided in the factory.
Die making machines : The machines which are involved are as under: 1. Lathe machine 2. Milling machine 3. Power hacksaw 4. Grinding machine 5. Drilling machine 6. Electric discharge machining (EDM) machine 7. CNC wire cut (for rimming dies) 8. Shaper 9. Electric arc welding set-up
Die materi al: -
Composition of the die materials used is as under:1.
DIN 2713 Carbon – 0.55 Silicon – 0.30 Manganese – 0.66
Phosphorus & sulphur – 0.035 Chromium – 0.70 Molybdenum – 0.30
Nickel – 1.70 Vanadium – 0.10
2. DIN 2714 Carbon – 0.56 Silicon – 0.30 Phosphorus & sulphur – 0.035 Molybdenum – 0.50 Nickel – 1.72 Vanadium – 0.10
Die making procedures:Block selection: - Here we have to select the size of the die block. For this we
have to check the number of cavities. Approximately 20 mm of gutter is provided around a cavity of size 100 – 125 mm. next thing is to check the thickness of the block for general pieces 70 mm thickness & half the clearances.
Block preparation: -
-
Automatic hand raw cutters are used to cut the blocks.
-
Both sides are given reference
-
Dove tail marking & machining is done.
-
No tool mark should be there.
- Impression marking & marking of other location is done by choosing one machined surface as datum surface. Primary machining: -
-
Facing is done on lathe machine
-
Impression turning is done on milling machine -
A hole is machined on both sides which are known as tong hole. Tong bars
are put into these holes & die can be easily lifted.
-
Then marking is done. Marking means drawing up the marks where
machining is done. It is done with the help of height gauge & surface plate. -
The cavity can be made by either machining on a milling machine or
by the help of an electrode on the EDM machine.
Pressing & polishing: - By using a hand grinder the grinding is done. Also the tool marks are removed. Carbide cutter is used. Polishing is done with iron stone to have better surface finish & also easy withdrawal.
Final inspection: -
- Dove-tail parallelity check - Dove-tail alignment check - Top surface level check - Dove-tail reference check
S hafts Power Take
Hydraulic Hollow Lift
off S hafts S hafts
S hafts
Live Power Take Off S hafts
Drive
Tie R od
S hafts As s embly
(i)Power Take off Shafts for Transmitting power from tractor to implements.
Utility Applicable Automobile Off Highway Agri Machinery
-
(ii)Hollow Shafts for transmitting power in the tractor and off highway vehicles.
Utility Applicable Automobile Off Highway Agri Machinery
-
(iii)Hydraulic Lift S hafts for transmitting power to lift arms.
Utility Applicable Automobile Off Highway Agri Machinery
-
 SINGH
3). Spur and Helical Gears
B ull G ears B ull Pi nion S hafts G ears for Gear B oxes (i) B ull Gears for torque transmission in off highway and tractors.
Utility Applicable Automobile Off Highway Agri
-
B ull Pinion S hafts

(ii) B ull Pi nion S hafts for transmitting torque in off highway vehicles.
Utility Applicable Automobile Off Highway Agri Machinery
-

(iii) G ears for Gear B oxes Utility Applicable Automobile
-
Off Highway Agri Machinery
-
4). E picyclic R eduction G ear
R ing G ears (x)
S pur S atellite G ears Flanges
R ing Gears for Epicyclic Reduction in off highway vehicles and tractors.
Utility A pplicable Automobile Off Highway Agri Machinery
-

S pur S atellite G ears
(ii) S pur Satellite G ears for Epicyclic Reduction.
Utility
Applicable
Automobile Off Highway Agri Machinery
-

Flanges (iii) Flanges for off highway transmission.
Utility Applicable Automobile Off Highway Agri Machinery
-
-
5). Hypoi d and B evel G ears Crown Wheel & HYP E R LINK " http://www.gnag roup.com/prod_hypoid1.htm" C rown Wheel & Pinion for
HYPERLINK "http://www.gnagroup.com/prod_hypoid2.htm" Crown Wheel & Pinion for
Pinion for Trucks
Off Hig hway
C ars and S UV
(i) C rown Wheel & P inion for Trucks Utility Applicable Automobile Off Highway Agri Machinery
-
(ii) Crown Wheel & P inion for Off Hig hway Utility Applicable Automobile Off Highway Agri Machinery
-

(iii) Crown Wheel & P inion for Cars and SUV Utility A pplicable Automobile Off Highway Agri Machinery
-
6).R ig ht Angle Drive Gear B oxes R ig ht A ngle Drives with 1 & 2 outputs in different gear ratio for various agriculture and other implements.
Utility Applicable Automobile Off Highway Agri Machinery
-
7). Propeller S haft A s s y & Components
Propeller S haft As s y. (xi) Pr opeller
Various components
S haft As s y. Of various sizes suitable for Cars, SUV’s, LCV and
heavy trucks upto 20 tonnes.
Utility Applicable Automobile Off Highway Ag ri Machinery
