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    Internship PPT at High Tech

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    Daksh Sirohi
    Daksh Sirohi presented on solving problems with a deburring machine at Hi-Tech Gears Ltd. Two main problems were identified: gears being cut by burr removal tools and unacceptable surface finishes. For gears being cut, the arm holding deburring tools had play, causing it to contact teeth. The proposed solution was to redesign the arm with bearings instead of pins to remove play. For surface finishes, tools were being moved below the gear depth, affecting earlier machining. A threaded screw was proposed to limit arm movement and prevent lowering tools too far. Creo models were created and changes were presented to address the issues and reduce gear rejections.

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    Internship PPT at High Tech

    Uploaded by

    Daksh Sirohi
    126 views19 pages
    Daksh Sirohi presented on solving problems with a deburring machine at Hi-Tech Gears Ltd. Two main problems were identified: gears being cut by burr removal tools and unacceptable surface finishes. For gears being cut, the arm holding deburring tools had play, causing it to contact teeth. The proposed solution was to redesign the arm with bearings instead of pins to remove play. For surface finishes, tools were being moved below the gear depth, affecting earlier machining. A threaded screw was proposed to limit arm movement and prevent lowering tools too far. Creo models were created and changes were presented to address the issues and reduce gear rejections.

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    intern ppt at high tech by iitian

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    Internship Ppt at high tech

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    Daksh Sirohi presented on solving problems with a deburring machine at Hi-Tech Gears Ltd. Two main problems were identified: gears being cut by burr removal tools and unacceptable surface finishes. For gears being cut, the arm holding deburring tools had play, causing it to contact teeth. The proposed solution was to redesign the arm with bearings instead of pins to remove play. For surface finishes, tools were being moved below the gear depth, affecting earlier machining. A threaded screw was proposed to limit arm movement and prevent lowering tools too far. Creo models were created and changes were presented to address the issues and reduce gear rejections.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    126 views19 pages

    Internship PPT at High Tech

    Uploaded by

    Daksh Sirohi
    Daksh Sirohi presented on solving problems with a deburring machine at Hi-Tech Gears Ltd. Two main problems were identified: gears being cut by burr removal tools and unacceptable surface finishes. For gears being cut, the arm holding deburring tools had play, causing it to contact teeth. The proposed solution was to redesign the arm with bearings instead of pins to remove play. For surface finishes, tools were being moved below the gear depth, affecting earlier machining. A threaded screw was proposed to limit arm movement and prevent lowering tools too far. Creo models were created and changes were presented to address the issues and reduce gear rejections.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 19

    SUMMER TRAINING PRESENTATION

    ON

    Identification and solution of the problems in


    deburring machine
    under mentorship
    of
    Mr. Anil Kumar Jain
    (manager-HR)

    HI-TECH GEARS LTD,BHIWADI

    By- Daksh Sirohi


    1301ME17

    ABOUT THE COMPANY

    HI-TECH GEARS LTD.

    ESTABLISHED IN 2001.

    JOINT VENTURE COMPANY OF GETRAG GEARS,USA & HITECH GEARS LTD,INDIA.

    50:50 PARTNERSHIP OF GETRAG GEARS,USA & HITECH GEARS LTD,INDIA.

    MANUFACTURES TWO & FOUR WHEELER TRANSMISSION SHAFTS & GEARS.

    FOREIGN CUSTOMERS INCLUDES US,AUSTRALIA ,JAPAN,GERMANY,BRAZIL,UK.

    INDIAN CUSTOMERS ARE HERO MOTO CORP LTD.,TATA CUMMINS,AVTEC NEW


    HOLLAND TRACTORS LTD.,ROBERT BOSCH.

    TOTAL SIX PLANTS OF HITECH GROUP IN INDIA .

    ANNUAL TURNOVER OF HITECH GROUP IS 60 BILLION RUPEES.

    Problem statement
    Identification and the solution of the Problems in Deburring
    Machine
    The rate of rejection of deburred gears was very high and objective was to
    reduce the rate of this rejection.

    Problem identification that caused the rejection of the gears

    Two types of problems were identified:

    Cutting of the gear teeth along with the burrs.

    Unacceptable surface finish.

    Solution strategy
    Think of as many ideas as possible and shortlist on the basis of following
    criterion:

    Cost

    Complication

    Production delay

    Technical shortcomings

    Space constraints

    From above procedure three ideas were proposed for each problem.

    Problem 1: Cutting of the gear teeth along with the burrs:


    It was found that during the deburring operation, the handle moved sideways due to the Play
    in it. Thats why the tool did not touch the gear at the target point instead it sometimes
    touched its teeth and thus the whole profile of the teeth was destroyed causing the complete
    rejection of the gear due to the cut on its teeth as shown in fig below:

    Following strategy was made in order to remove this problem:


    The

    pin joint about which the arm move should be redesigned such that the
    play is removed completely
    The weight of the arm was very large due to which the spring supporting the
    arm often got wear off therefore its weight was to be minimized
    Following above, it was decided that the Arm of the deburring Machine should
    be redesigned.
    In making the new design of the arm, it was necessary to keep into account the
    fact that:
    The design should be such that it can be integrated to the Deburring Machine
    without disturbing the production.
    Also the design should be such that the arm can be mounted on the existing
    cross slide

    Creo parametric model:


    Before making the final drawings for the parts of the Arm, the whole assembly
    was modeled and simulated using Creo Parametric. All the parts were made
    separately and were assembled. The whole assembly included eight parts
    1. Base part: The part on which the housing will be mounted is the base part and
    is the existing base part with only change in the number of holes and their
    position.

    2. Bearing housing:Bearing housing was designed such that it is fitted to the


    existing base and is dimensioned accordingly. Two such housings will be used in
    final assembly.

    3. Arm: The arm design is completely different from previous design. In this new
    design the weight of arm is kept as low as possible so that the fatigue work is
    low.

    4. Handle:The handle is designed such that the grip of the operator is


    significantly large as compared to the previous design:

    5. Shaft: Shaft is such that its diameter is in interference fitting with the
    bearing. It is also completely different than the previous one and is shown as
    under

    6. Spring: Spring is designed to keep the fatigue work of the operator to the
    lowest level. Two such springs will be used.

    7. Two spring blockers and one spring leg blocker: Both of these part are to
    confine the spring from both ends so that a sufficient stress is generated in it
    that help the arm to come to its initial position.

    8. Bearings: Bearing are the most important parts in the new design because we
    replaced the previous pin joint with bearings. As there are two housing installed on
    the base part, each housing has two bearing that will be installed in it. Thus total
    of 4 bearings are used that reduced the play to zero. Bearing no is given as:

    Final assembly
    4 x (6302ZE NACHI deep groove ball bearing)

    Problem 2: Unacceptable surface finish:


    In this problem as the machine is operated for the deburring of the
    gears, it is very likely that the operator moves the tool below the
    dedendum circle of the gear which is the limiting depth to which the
    tool can be moved. If the tool is brought below this particular depth, the
    facing of the one side of gear starts affecting the surface finish that was
    obtained from the machining process. Thus the surface finish that was
    obtained from the machining process gets disturbed which ultimately
    causes the rejection of the parts. This problem occurs because of the
    absence of any mechanism that may stops the tool to move below a
    certain limit.
    As given previously the best idea to solve this problem was selected as to
    use threaded screw for stopping the arm.

    Threaded screw:
    Threaded screw is suitable solution for this problem. It has many
    advantage in its use as:

    can be easily adjusted for different sizes of Gears to be deburred.

    It will not affect the space for placing the gears.

    It can be readily installed on the bed of the machine.

    THANK YOU

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