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