NC GASOLINE ENGINE ANALYTICAL CENTER

CHAPTER – I

COMPANY PROFILE:

Nc gasoline engine analytical center was founded in 2002, The Company CEO
A.AnwareJallal. Managing Director in A.Mohamed Riyas, and is operating as the
prominent manufacturer and supplier of a varied range of Gearboxes & Transmission
Components. Offered product range comprises Gear Boxes, Mechanical Gears and Gear
Racks. The offered products are manufactured by using supreme quality materials and
offered highly admired by the patrons for being in line with the predefined industry norms.
These products are well known for their high quality, long service life and sturdy
construction features. The offered products find wide application in different hard industries.
The company total Employees, 420.

We have an ultra-modern infrastructural facility and running all the process reliable and
interrupt free production rate of the offered products. We bought the raw materials for the
provided products from the authentic supplier of this domain. Our warehouse facility is
capable of accommodating bulk quantities these products due to the ample space provided.
We have a wide distribution network for timely delivery of orders. Our organization is
famous for its customer-centric approach and thus we have huge client base in the market.

We understand the challenges of successfully competing in the Indian manufacturing

marketplace. To insure our customer’s success in this arena, we leverage our engineering
expertise, manufacturing experience and technological assets.

These factors, combined with solid relationships with our own suppliers, provide the stability
that our customers need in a contract manufacturer.
We seek to grow in expertise and technological capabilities such that we can add value to our
products for our customers. The customers always benefits from the excellence in production
of high quality components being manufactured by the company over last two decades.

INTRODUCTION ABOUT THE INDUSTRY:

The purpose of production activity is to create added value. This also applies to gear
manufacturing, and added value creation is conducted through production control for the
purpose of achieving QCD (quality, cost, volume and deadline), including everything from
the procurement of raw materials such as round bars for cylindrical gears and squared timber
for racks to the packaging and shipping of the final products, namely gears.

The production process required for gear manufacturing covers a lot of ground, but general
examples which can be given include cutting of materials with cutting machines, processing
of materials with lathes, cutting of cylindrical gear teeth with hobbing machines, cutting of
rack teeth with rack panels, cutting of internal gear teeth with gear shapers, deburring, and
blackening, etc. In gear manufacturing processes other than machining mentioned above are
also used such as injection molding, sintering, rolling, and casting. Furthermore, polishing,
tempering, surface processing, teeth shape measurement, and examination with 3D
measurement devices are also components of production activity.

What is a Gear Shaper?

A gear shaper is a type of gear cutting machine. When cutting cylindrical gears such as
helical gears and spur gears, cutting of the teeth on the workpiece is performed by hobbing
with a rotating hob (see Fig. 2) or gear shaping with a reciprocating pinion cutter (see Fig. 3).

Hobbing is inherently more efficient because the hob performs cutting the workpiece
continuously. Gear shaping is less efficient because the reciprocating motion of the pinion
cutter only performs cutting one-third of the time. On the other hand, its advantages are that it
can be used for the machining of internal teeth and where there are obstructions in the
vicinity of the gear. A stepped gear shown in Fig. 3, for example, can only be machined by a
gear shaper.
Hobbing

Gear Machine Tool Product Range

A range of gear cutting machines is needed to satisfy customer orders for “packs.” While
hobbing machines can be sourced from a partner supplier, shaping machines must be
produced in-house because they are not available from any of Kanzaki’s partners in Japan.
This has created the need for a range of shaping machines in order to satisfy “packs” orders.
A competing supplier has a near monopoly on gear shapers in Japan with more than 80% of
the market. Drawing on feedback from customers, Kanzaki identified the following three
design concepts.

Compact design

Simple, low cost

Compliance with JIS Grade N7 accuracy

Fig. 4. CA100 Gear Shaper

Compact and with Simple Features

One of the features of the newly developed gear shaper is its use of a table feed method. This
means that the workpiece is cut by moving it toward the cutter while the cutter remains
stationary. This is in contrast to the currently more common column-feed method where the
workpiece remains fixed and is cut by moving the column.

Using the table feed method helps reduce the size and cost of the machine by enabling the
column and bed to be combined.

To simplify the design, the height adjustment for cutter regrinding is performed manually
rather than by numeric control, providing a wide adjustment range. Another feature of the
machine is that it is designed to allow a wide range of machining positions (heights) while it
does not use a high column configuration and it can be used for both internal and external
workpiece cutting.
As shown in Fig. 6, the gear shaper can achieve the target machining accuracy even when

working at 2000st･min-1.

Fig. 6. Gear Shaper Machining Accuracy

Column Feed Method

Fig. 8. Table Feed Method

What is a Gear Grinder?

Gear grinders are finishing machines that use a grinding wheel rotating at high speed to grind
the surface of the gear (workpiece) teeth.

Gear grinders can be broadly divided into continuously generation grinders and profile
grinders. Continuously generation grinding uses a tool (grinding worm) with a different
profile than the gear teeth and performs grinding by moving the workpiece and grinding
worm relative to one another. Profile grinding, on the other hand, grinds the workpiece using
a tool with the same profile as the gear teeth.

Continuously generation grinding uses a grinding worm with multiple threads, and machining
productivity can be increased by increasing the number of threads. Accordingly, continuously
generation grinders are used at automotive and other mass production facilities. The GB150
model is a continuously generation grinder and is intended for mass production facilities.
Fig. 9. Continuously Generating Grinding
Profile Grinding

Compact Design Achieved by Focusing on Specific Markets

One of the features of the GB150 grinding machine (see Figs. 11 and 12) is its compact size.

The target market for the machine is limited to pinion gears for vehicle automatic
transmissions and small module gears for industrial machinery (M2, gear diameters of 150
mm or less). This focus on a clear target market enables the machine to be made more
compact because individual parts can be sized appropriately. This helps shrink the size of
customers’

How to make the gears used in automotive drive trains quieter has been a subject of interest
in recent years. The emergence of hybrid and electric vehicles has focused attention on the
acoustic noise produced by the transmission. To reduce noises such as whine and the striking
noise made by gear meshing, manufacturers have adopted practices such as controlling heat
treatment distortion and selecting pairs of opposing gears based on how accurately they mesh
together. Another more dependable practice that is emerging is to perform finishing of the
gears after heat treatment. Post-heat-treatment finishing of gears by grinding or honing
practices that were rare in the past, are now becoming more common. Improvement in
cumulative pitch accuracy, another cause of noise, is an emerging requirement and gear
grinding machines and synchronized honing machines can meet this requirement. On the
other hand, as improvements in the performance of grindstones has enabled machining to
remove more material in the finishing process, there are also cases where shaving is no longer
used.

Gears are used in all types of machinery. They can be as small as 3mm diameter to 11m
diameter. They are used to transmit rotary motion from one shaft to another by means of
toothed wheels, which are in direct mesh with each other. In contrast, chain wheels transmit
motion from one wheel to another by means of chain connection. They are called sprockets.
Gears are used for power transmission as in automobile gearbox and in control elements.

Spur gears:

Spur gears are the most commonly used gears, are used to transmit motion between parallel
shafts. These impose load on bearings. Its teeth are straight and parallel to the axis. These can
be either internal type or external type. An external spur gear of infinite radius, called as rack.
Rack has straight-sided tooth (for involute tooth profile gears).

Helical gears:

In helical gears, the tooth profile in transverse plane gets gradually rotated along the helix
angle as we move along the axis. The hand of the helix determines whether it is a right
handed helical gear or a left handed helical gear. Helical gears can be external or internal
type. However, internal helical gears are not very common in external helical gears, the hands
of the mating gears are of opposite hands, whereas for internal helical gear meshing with
external gear, they are of the same hand. The mating gear should always have the same helix
angle.
Sometimes double helical gears are also used where they have both right handed and left
handed helical teeth on each gear. Normally there is a gap between the two helices. However,
there are gears which have no gap between the helices double helical gear are also called
chevron gears. Single helical gear impose both radial and thrust load on bearings. Double
helical gear normally impose radial loads as the thrust loads due to opposite helices are in the
opposite directions and, therefore, they cancel out. The spur gears can be considered as a
special case of gears with helix angle equal to zero.

VISION

“To enhance customer satisfaction and our image globally and achieve exponential growth to
leadership through world class products and service.”

MISSION

“To deliver greater value to our customers by providing complete competitive solutions
through technological leadership and manufacturing excellence that are responsive to
dynamic market needs.”

VALUES

Excellence
Integrity
Learning and sharing
Contribution to industry and society