CHAPTER-1

COMPANY PROFILE
GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd, as it
was then known, was established. Three years later the company became the first in India to
manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ supplier
for Maruti Suzuki at that time the only front wheel drive car manufacturer of the country.
Later known as GKN Drive shafts (India) Ltd, the operation became a owned subsidiary of
GKN Driveline in 2002 and is today the side shaft market leader in India with an installed
capacity to manufacture over one million units (half a million vehicle sets) a year. Sales in
2003 stood at more than 23 million pound.
The companys growth in the 1990s was strongly linked with its supply of side shafts for the
Government of Indias joint venture with Japanese car maker Suzuki Motor Corporation to
make front wheel drive cars. Beginning with the Suzuki Maruti 800cc model in 1989,
production rapidly expanded and GKN currently supplies all front wheel drive cars for the
company (800cc, Zen, Wagon-R. Gypsy, Esteem, Baleno and Swift)
During the late 90s GKN Driveline India began supplying product for other major customers.
In 1996 it was selected sole supplier to Fiat (Uno, Siena and Palio models) and Ford
(Escorts/Ikon) in India. Two years later it became sole supplier to Korean manufacturer
Hyundai Motors ( Santro , Accent, Sonata and Getz) and began working with Tata Motors
( Indica ), one of the largest business house in India. In 2000 Honda (City) and General
Motors (Corsa) were added to the customer base.
1.1 VISION & VALUES
THIS IS GKN

Technology and engineering from GKN is at the heart of the vehicles and

aircraft produced

by the worlds leading automotive and aerospace manufacturers.

More than 50,000 peoples work in GKN companies and joint ventures in more than 37
countries. Everyday we harness our considerable technology and manufacturing resources to
supply the highest quality systems, structures, components and services
When we fulfill the trust of our customers place in us then we can enrich our Shareholders
reward our people and support our communities.
And because we respect the environment and the dignity and human rights of others we are
building a business, which can be sustained by future generations.
Everyone involved with a great company should expect nothing less. But those with a Stake in
the performance of GKN should expect more.
21st century global leadership in our four major businesses, when our
History spans more than 250 years, speaks for standards of agility, innovation and excellence,
which would be difficult to surpass.
Customer and quality
To provide excellent and continuously improving products and services to exceed our
customers expectations.
To be the best in class in terms of value through quality, technology, speed, performance and
innovation.
To treat our suppliers fairly as an integral part of our total capability to serve our customers.
1.2 Enterprise and Innovation
To foster the spirit of enterprise

To grow profitability by managing risk, being innovative and

using initiative

To move with speed in our business processes.

To inspire outstanding performance from teams and individuals and to recognize and
appropriately reward achievement.

To encourage employees to fulfill the potential for the benefit of both themselves and the
organization.

To foster teamwork and individual achievement within a culture of empowerment and

accountability.

To share knowledge and best practice across our companies to stimulate the creation of
new business opportunities.

To provide equal opportunity irrespective of sex, sexual orientation, disability, Religion

or ethnic origin.

To provide a safe environment.

1.3 Community, environment and business ethics

To act with integrity at all times
To meet standards of good corporate governance.
To play our part in safeguarding the environment
To contribute positively to the communities in which we operate.

1.4 PLANT
IN INDIA THERE ARE THREE PLANTS OF GKN WHICH ARE LOCATED AT
DIFFERENT SITES IN THE

COUNTRY

FARIDABAD PLANT

DHARUHERA PLAN

ORAGADAM PLANT

1.5 FARIDABAD PLANT

GKN Driveline India traces its origin back to 1986 when Invel Transmissions Ltd, as
It was known, was established. Three years later the company became the first in India
To manufacture side shafts for front wheel drive vehicles when it was selected sole CVJ
Supplier for Maruti Suzuki at that time the only front wheel drive car manufacturer in
the country
Faridabad plant is the mother plant in the country. Plant is situated in sector-24,
Faridabad. This plant is 30 km away from the national capital. This plant acquired a area
about 40,000Sqm. 280peoples are working here. This plant is established in 1986 and the
production starts from April 1989. In all of the other three-plant Faridabad plant is the
major plant. Faridabad plant is the manufacturing plant. All the sub-parts are made here.

1.6 DHARUHERA PLANT

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This plant is set-up in14th January 1997. This plant acquired a area about 68,000Sqm.
The built up area is about 4,500Sqm.It is 75 km away from the national capital. There are
over 150 employees at the plant which has responsibility for side shaft assembly and
delivers to customers Maruti Suzuki, Tata Motors, Honda, General Motors and Fiat.
In this plant GI joints are manufactured. Most of the assemblies like bell, tripod, pot, and
shafts are done here.

1.7 ORAGADAM PLANT

Plant is established in 1st April, 1996.It is situated 60 kilometers from Chennai, and it has
22 employees and two assembly lines for JIT supply requirements for customers Hyundai
and ford. This plant acquired a area about 4000Sqm. In which built up area is 2000Sqm.
GDI LOCATIONS
Dharuhera

Faridabad

Fig. 1.1 GDI Location

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Fig. 1.2 GDI: Faridabad Plant

Commenced operation on 13th April, 1989
Land area 40,000sqm (Built-up 15,500sqm)
Manpower 339

Fig. 1.3 GDI: Dharuhera Plant

Commenced operation on 14th January, 1997

Land Area 68,800sqm (Built-up 4,500sqm)
Manpower 150

Fig. 1.4 GDI: Oragadam Plant

Commenced operation on 1st April, 1996
Land Area 4,000sqm (Built-up 2,000sqm)
Manpower 205

1.8 GKN HISTORY

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GKN

DRIVESHAFTS

(INDIA)

LTD

formerly

known

as

GKN

INVEL

TRANSMISSION LTD was formed in the year 1986 was promoted in 1988 by GKN plc.
and started commercial production in April 1989.
In November 1995 Invel became a subsidiary company of GKNADD (Automotive
Driveline Division) who, with facilities all over the world, fulfills a large proportion of
the worlds demand for CV joints.
The company manufactures drive shafts assemblies made of constant velocity (CV) joints
for front wheel drive and four wheel drive vehicles, mainly passenger cars.
The sophisticated high precision GKN technology required by ball and tripod joint is
supported by some of the latest manufacturing and testing equipment to ensure the
highest level of accuracy in every joint coming off the assembly line from completely
integrated production facilities.
The Faridabad plant has full range of facilities used for the manufacturing of bell
assembly, Inner race and DSA. This includes heat treatment and a testing facility
available for the validation of the product from all of the other facilities.
The Dharuhera plant has facilities for the manufacturing of Connecting Driveshaft,
Tripod, Tulip and complete assembly of CV joints with the exception of the tent house
and heat treatment.
The Gummidipundi plant assembly facility is effectively an additional assembly cell of
Dharuhera, assembling product and shipping complete driveshaft to local customers.
All the three plants are 1SO9002/ QS9000 & ISO14001 Certified. The company is trying
to get TS16949 Certification.
The company has got over 70% markets in the CV Joints in India & over 45%
worldwide.

1.9 GKN PLC

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GKN plc. is an international group of companies with a turnover of around 4.3 billion
pounds. The group designs, develops and manufactures automotive components as well
aerospace and defense products. The group provides a range of industrial services.
GKNs operations are located in more than 30 countries around the world and the group
employs around 36,000 people.
The automotive and agricultural products business area is the largest within the
group accounting for over 60% of total turnover. Industrial services and aerospace and
special vehicles each generate approximately 20% of the groups total turnover.
The name GKN is derived from Guest, Keen and Nettlefolds. Its history dates back
to 1759. Starting in iron making and coal mining, the group progressed into steel and its
many derivatives, serving the railways, building and construction, automotive and other
major industries. Although once world renowned steel maker and producer of screws and
fasteners, the group has been through many changes over the last 25 years in response to
fundamental shifts in these traditional markets.

1.10 GKN DRIVELINE

GKN is a leading global supplier to the worlds automotive, off highway and aerospace
manufacturers. GKN provides technology-based, highly engineered products to virtually
all of the world's major manufacturers of light vehicles, agricultural and construction
equipment, aircraft and aero engines. Almost 38,000 people work in GKN companies and
joint ventures in more than 30 countries
GKN is a multinational engineering company headquartered in Red ditch, United
Kingdom. The company was formerly known as Guest, Keen and Nettle folds and can
trace its origins back to 1759 and the birth of the industrial revolution. In 2009 the
company celebrated its 250th anniversary.
GKN Driveline India LTD traces its origin back to 1986 when Invel Transmissions Ltd,
as it was then known, was established. Three years later the company became the first in
India to manufacture side shafts for front wheel drive vehicles when it was selected sole
CVJ supplier for Maruti Suzuki at that time the only front wheel drive car manufacturer
of the country.

Later known as GKN Driveshaft (India) Ltd, the operation became a owned subsidiary of
GKN Driveline in 2002 and is today the sideshaft market leader in India with an installed
capacity to manufacture over one million units (half a million vehicle sets) a year. Sales
in 2003 stood at more than 23 million pound.
The companys growth in the 1990s was strongly linked with its supply of sideshafts for
the Government of Indias joint venture with Japanese car maker Suzuki Motor
Corporation to make front wheel drive cars. Beginning with the Suzuki Maruti 800cc
model in 1989, production rapidly expanded and GKN currently supplies all front wheel
drive cars for the company (800cc, Zen, Wagon-R. Gypsy, Esteem, Baleno and Swift)
During the late 90s GKN Driveline India began supplying product for other major
customers. In 1996 it was selected sole supplier to Fiat (Uno, Siena and Palio models)
and Ford (Escorts/Ikon) in India. Two years later it became sole supplier to Korean
manufacturer Hyundai Motors (Santro, Accent, Sonata and Getz) and began working with
Tata Motors (Indica), one of the largest business house in India. In 2000 Honda (City)
and General Motors (Corsa) were added to the customer base.

CHAPTER-2
9

GKN DRIVELINE PRODUCTS

2.1 Products
GKN Driveline is the world leader in the design and production of driveline components.
Producing systems and components for small front wheel drive to the most sophisticated
four wheel drive vehicles, GKN Driveline has the products to achieve the optimum
driveline solution.
With these products comes technical expertise and an understanding of all aspects that
affect vehicle dynamics and how these can be optimized for weight and performance
improvement.

CVJ Side shaft

Premium Prop shafts

Geared Power Transmission Products

Torque Management Devices

Replacement Parts

Motorsport Products

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2.2 Solution Finder

GKN Driveline has a wide range of products across the vehicle driveline to meet most
vehicle configurations.
With torque products for every axle, front and rear sideshafts and propshafts from one
piece to three pieces - we are sure to have a solution for you.
Select the vehicle configuration you need from the list below to see what solutions GKN
Driveline can offer:

2.3 Premium Propshafts

GKN Driveline offers an entire portfolio of propshaft solutions for passenger cars and
light commercial vehicles. They are tailored, tuned and harmonized to suit the
characteristics and performance requirements of each application. Each propshaft is a
unique, engineered product.
Configuration Examples

High Speed Fixed Constant Velocity Joints (CVJ)

High Speed Plunging Constant Velocity Joints (CVJ)

Cardan Joints

Other Components
Configuration Examples

High Speed Joints

Other Components

2.4 CVJ Sideshafts

GKN Driveline CVJ sideshafts transfer the engine power transversely from the gearbox
to the wheel ends on front wheel, rear wheel and four wheel drive applications. They are
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optimized for weight, noise, vibration, harshness (NVH), steering and suspension
performance.
GKN Driveline has a unique range of CVJ sideshaft configurations to meet the needs of
all types of vehicle.

Sideshaft CV Joints

Interconnecting Shafts and Boots

Configuration Examples

2.5 Sideshaft
A sideshaft is a system that transfers torque from a differential to the driven wheels
allowing wheel movement due to steering or suspension movement. This system has
three major elements:

Inboard Constant Velocity Joint (CVJ)

Interconnecting shaft

Outboard Constant Velocity Joint (CVJ)

In most applications, the inboard CV Joint is a plunge joint that allows the effective
length of the sideshaft to change due to suspension travel. In front (or steer) axle
applications, the outboard joint must transfer torque effectively through a wide angle (up
to 52 degrees). In rear axle applications, joint operating angles are much lower
2.6 Geared Power Transmission Products
GKN Drivelines range of power transmission products ensure that driving torque is
constantly transmitted to driving wheels at maximum efficiency, to provide unsurpassed
levels of responsiveness and reliability.

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The range of geared products includes final drive units, which transfer torque from
propshaft to wheels in rear- and all-wheel drive (AWD) vehicles, and power transfer
units, which distribute torque between front and rear axles in AWD configurations.

Power Transfer Unit

Final Drive Unit

Differentials

Dual Differential

Drive Module for Motor Assisted 4WD

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2.6 Power Transfer Unit

Fig.2.1 Power Transfer Unit

GKN Drivelines robust and versatile Power Transfer Units provide full-time or ondemand AWD torque distribution for front wheel-drive based AWD systems. Tailored
designs provided compact and cost effective AWD driveline solutions.
2.7 Benefits

Aluminum construction

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Compact designs

Used in front-wheel drive based vehicles with transverse engine mount

Available in part-time, full-time and on-demand AWD configurations

Available installation of various differential or coupling

2.8 Final Drive Unit

Fig. 2.2 Final Drive Unit

GKN Drivelines proven and reliable Final Drive Units (FDU) for front and rear
independent axle applications, offer robust performance and versatility for allwheel-drive and real-wheel-drive drivelines.

2.9 Differentials

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Fig. 2.3 Differentials

GKN Driveline offers a wide range of open bevel gear differentials for use in passenger
cars, sport utility vehicles (SUVs) and light truck transmissions of final drive units.
Design Features

Available in eight sizes ranging from 3.000 to 20.000 Nm differential input torque

Available in both 2-pinion and 4-pinion design

Bevel gears are either cut or cold formed

Compact and cost competitive designs

2.10 SUPPLIER NETWORK

Company has 17 local direct material suppliers, 21 overseas direct material suppliers, 15
local sub contractors & over 300 suppliers for In-direct materials. In indirect material
suppliers there are 238 local suppliers, 42 technical service providers & 19 general
service providers.
Budget for direct material is made every year based on the customer forecast & based on
the budget for direct material Purchase planning is made.

2.11 BRIEF DESCRIPTION OF MAJOR COMPONENTS

Major components required for manufacturing of Driveshafts are Outer Race (Bell), Inner
Race, Cage, Tulip, Shaft, Male & Female pot. Besides these other components are
Tripod, Rubber boot, Clamps, Steel Balls, Damper, needle roller Bearings,
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2.12 Drive Line Shaft

A drive shaft, driveshaft, driving shaft, propeller shaft (prop shaft), or Cardan
shaft is a mechanical component for transmitting torque and rotation, usually used to
connect other components of a drive train that cannot be connected directly because of
distance or the need to allow for relative movement between them.
As torque carriers, drive shafts are subject to torsion and shear stress, equivalent to the
difference between the input torque and the load. They must therefore be strong enough
to bear the stress, whilst avoiding too much additional weight as that would in turn
increase their inertia.
To allow for variations in the alignment and distance between the driving and driven
components, drive shafts frequently incorporate one or more universal joints, jaw
couplings, or rag joints, and sometimes a splined joint orprismatic joint.

Fig. 2.4 Drive Line Shaft

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The term drive shaft first appeared during the mid 19th century. In Storer's 1861 patent
reissue for a planing and matching machine, the term is used to refer to the belt-driven
shaft by which the machine is driven. [1] The term is not used in his original patent.
[2]

Another early use of the term occurs in the 1861 patent reissue for the Watkins and

Bryson horse-drawn mowing machine.[3] Here, the term refers to the shaft transmitting
power from the machine's wheels to the gear train that works the cutting mechanism.
In the 1890s, the term began to be used in a manner closer to the modern sense. In 1891,
for example, Battles referred to the shaft between the transmission and driving trucks of
his Climax locomotive as the drive shaft,[4] and Stillman referred to the shaft linking the
crankshaft to the rear axle of his shaft-driven bicycle as a drive shaft.[5] In 1899, Bukey
used the term to describe the shaft transmitting power from the wheel to the driven
machinery by a universal joint in his Horse-Power.[6] In the same year, Clark described
his Marine Velocipede using the term to refer to the gear-driven shaft transmitting power
through a universal joint to the propeller shaft.[7] Crompton used the term to refer to the
shaft between the transmission of his steam-powered Motor Vehicle of 1903 and the
driven axle.[8]

2.13 Automotive drive shaft

An automobile may use a longitudinal shaft to deliver power from an engine/transmission
to the other end of the vehicle before it goes to the wheels. A pair of short drive shafts is
commonly used to send power from a central differential, transmission, or transaxle to the
wheels.

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Fig. 2.5 double propeller shaft

2.14 engine, rear-wheel drive

In front-engined, rear-drive vehicles, a longer drive shaft is also required to send power
the length of the vehicle. Two forms dominate: The torque tube with a single universal
joint and the more common Hotchkiss drive with two or more joints. This system became
known as Systme Panhard after the automobile company Panhard et Levassor patented
it.
Most of these vehicles have a clutch and gearbox (or transmission) mounted directly on
the engine with a drive shaft leading to a final drive in the rear axle. When the vehicle is
stationary, the drive shaft does not rotate. A few, mostly sports, cars seeking improved
weight balance between front and rear, and most commonly Alfa Romeos or Porsche
924s, have instead used a rear-mounted transaxle. This places the clutch and transmission
at the rear of the car and the drive shaft between them and the engine. In this case the
drive shaft rotates continuously as long as the engine does, even when the car is
stationary and out of gear.
A drive shaft connecting a rear differential to a rear wheel may be called a half-shaft. The
name derives from the fact that two such shafts are required to form onerear axle.

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Early automobiles often used chain drive or belt drive mechanisms rather than a drive
shaft. Some used electrical generators and motors to transmit power to the wheels.

2.15 Front-wheel drive

In British English, the term "drive shaft" is restricted to a transverse shaft that transmits
power to the wheels, especially the front wheels. A drive shaft connecting the gearbox to
a rear differential is called a propeller shaft, or prop-shaft. A prop-shaft assembly
consists of a propeller shaft, a slip joint and one or more universal joints. Where the
engine and axles are separated from each other, as on four-wheel drive and rear-wheel
drive vehicles, it is the propeller shaft that serves to transmit the drive force generated by
the engine to the axles.
Several different types of drive shaft are used in the automotive industry:

One-piece drive shaft

Two-piece drive shaft

Slip-in-tube drive shaft

The slip-in-tube drive shaft is a new type that improves crash safety. It can be compressed
to absorb energy in the event of a crash, so is also known as a collapsible drive shaft.

2.16 Four wheel and all-wheel drive

These evolved from the front-engine rear-wheel drive layout. A new form of transmission
called the transfer case was placed between transmission and final drives in both axles.
This split the drive to the two axles and may also have included reduction gears, a dog
clutch or differential. At least two drive shafts were used, one from the transfer case to
each axle. In some larger vehicles, the transfer box was centrally mounted and was itself
driven by a short drive shaft. In vehicles the size of a Land Rover, the drive shaft to the
front axle is noticeably shorter and more steeply articulated than the rear shaft, making it

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a more difficult engineering problem to build a reliable drive shaft, and which may
involve a more sophisticated form of universal joint.
Modern light cars with all-wheel drive (notably Audi or the Fiat Panda) may use a system
that more closely resembles a front-wheel drive layout. The transmission and final drive
for the front axle are combined into one housing alongside the engine, and a single drive
shaft runs the length of the car to the rear axle. This is a favoured design where the torque
is biased to the front wheels to give car-like handling, or where the maker wishes to
produce both four-wheel drive and front-wheel drive cars with many shared components.

2.17 Drive shaft for Research and Development (R&D)

The automotive industry also uses drive shafts at testing plants. At an engine test stand a
drive shaft is used to transfer a certain speed / torque from the Internal combustion
engine to a dynamometer. A "shaft guard" is used at a shaft connection to protect against
contact with the drive shaft and for detection of a shaft failure. At a transmission test
stand a drive shaft connects the prime mover with the transmission.

2.18 Motorcycle drive shafts

Drive shafts have been used on motorcycles since before WW1, such as the Belgian FN
motorcycle from 1903 and theStuart Turner Stellar motorcycle of 1912. As an alternative
to chain and belt drives, drive shafts offer relatively maintenance-free operation, long life
21

and cleanliness. A disadvantage of shaft drive on a motorcycle is that helical

gearing, spiral bevel gearing or similar is needed to turn the power 90 from the shaft to
the rear wheel, losing some power in the process. On the other hand, it is easier to protect
the shaft linkages and drive gears from dust, sand, and mud.
BMW has produced shaft drive motorcycles since 1923; and Moto Guzzi have built
shaft-drive V-twins since the 1960s. The British company, Triumph and the major
Japanese brands, Honda, Suzuki, Kawasaki and Yamaha, have produced shaft drive
motorcycles. All geared models of the Vespa scooter produced to date have been shaftdriven. Vespa's automatic models, however, use a belt.
Motorcycle engines positioned such that the crankshaft is longitudinal and parallel to the
frame are often used for shaft-driven motorcycles. This requires only one 90 turn in
power transmission, rather than two. Bikes from Moto Guzzi and BMW, plus
the Triumph Rocket III and Honda ST series all use this engine layout.
Motorcycles with shaft drive are subject to shaft effect where the chassis climbs when
power is applied. This effect, which is the opposite of that exhibited by chain-drive
motorcycles, is

counteracted with systems

such as BMW's Paralever, Moto

Guzzi's CARC and Kawasaki's Tetra Lever.

2.19 Marine drive shafts

On a power-driven ship, the drive shaft, or propeller shaft, usually connects the
transmission inside the vessel directly to the propeller, passing through a stuffing box or
other seal at the point it exits the hull. There is also a thrust block, a bearing to resist the
axial force of the propeller. As the rotating propeller pushes the vessel forward, any
length of drive shaft between propeller and thrust block is subject to compression, and
when going astern to tension. Except for the very smallest of boats, this force isn't taken
on the gearbox or engine directly.
Cardan shafts are also often used in marine applications between the transmission and
either a propeller gearbox or waterjet.
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2.20 Locomotive drive shafts

The Shay, Climax and Heisler locomotives, all introduced in the late 19th century,
used quill drives to couple power from a centrally mounted multi-cylinder engine to each
of the trucks supporting the engine. On each of these geared steam locomotives, one end
of each drive shaft was coupled to the driven truck through a universal joint while the
other end was powered by the crankshaft, transmission or another truck through a second
universal joint. A quill drive also has the ability to slide lengthways, effectively varying
its length. This is required to allow the bogies to rotate when passing a curve.
Cardan shafts are used in some diesel locomotives (mainly diesel-hydraulics, such
as British Rail Class 52) and someelectric locomotives (e.g. British Rail Class 91). They
are also widely used in diesel multiple units.

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2.21 Drive shafts in bicycles

.
The drive shaft has served as an alternative to a chain-drive in bicycles for the past
century, never becoming very popular. A shaft-driven bicycle (or "Acatane", from an
early maker) has several advantages and disadvantages:
Advantage

Drive system is less likely to become jammed, a common problem with chaindriven bicycles

The rider cannot become dirtied from chain grease or injured by "Chain bite"
when clothing or a body part catches between an unguarded chain and a sprocket

Lower maintenance than a chain system when the drive shaft is enclosed in a tube

More consistent performance. Dynamic Bicycles claims that a drive shaft bicycle
can deliver 94% efficiency, whereas a chain-driven bike can deliver anywhere from
75-97% efficiency based on condition

Greater ground clearance: lacking a derailleur or other low-hanging machinery,

the bicycle has nearly twice the ground clearance

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Disadvantages

A drive shaft system weighs more than a chain system, usually 1-2 pounds heavier

Many of the advantages claimed by drive shaft's proponents can be achieved on a

chain-driven bicycle, such as covering the chain and gears

Use of lightweight derailleur gears with a high number of ratios is impossible,

although hub gears can be used

Wheel removal can be complicated in some designs (as it is for some chain-driven
bicycles with hub gears).

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REFERENCES
www.google.com
www.wikipedia.com
www.mechanicalengineering.com

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