SUMMER TRAINING PROJECT

“TO INCREASE THE ACCEPTANCE LEVEL OF GEARS”

CO M PL ETED AT

INTERNATIONAL TRACTORS LTD. (SONALIKA TRACTORS)

HOSHIARPUR , PUNJAB
DURING
MAY 26 , 2016 – JULY 14 , 2016
BY
HARDIP SINGH
13109074
INTERNATIONAL TRACTORS LTD. (SONALIKA)
Sonalika International Tractors Ltd. Is the country’s heavy duty tractor
manufacturing company that produces bestselling tractors between 20
HP to 110 HP. Today Sonalika is the third largest player in the domestic
market . Sonalika ITL is recognized in both domestic and international
market as a formidable player. The company has earned trust of more
than 7 lakh patrons in more than 100 countries across the globe. It is the
only company present in 80 countries and is most preferred tractor
company internationally.
Sonalika ITL boasts State-of-the-art integrated tractor manufacturing
plant, situated in Hoshiarpur with capacity of manufacturing 2 lakh
tractors annually.
 INTRODUCTION TO PROJECT

• Project Title : To increase Acceptance level of Gears.

• Project Objective : Manufacture gears with outmost care so that

they have maximum chance of acceptance at testing stage.

• Project Description : The project relates to manufacturing of gears

at ITL and analyzing where in the manufacturing stage lies the
reason of problems due to which gears are rejected and propose
solutions for the same
GEAR’S MANUFACTURING PROCESS
• CASTING
• EXTRUSION
1. FORMING • FORGING etc.

• BROACHING
• HOBBING
2. MACHINING • GEAR SHAPING

• SHAVING
3. FINISHING
• DE-BURRING
 HEAT TREATMENT

GAS
WASHING PRE-HEATING QUENCHING WASHING TEMPERING
CARBURIZING

POST HEAT TREATMENT FINISHING PROCESSES :

MISCELLANEOUS
POST LAPPING &
SHOT BLASTING CORRECTIVE
DEBURRING HONING
PROCESSES
DATA OF REJECTED GEARS
REASONS FOR REJECTION OF GEAR

From the above analyzed data , we observed that Gear Box are
rejected and disassembled because of two main problems :-

• Collar bent of Z-38 , Z-24 gear , which moves axially on the

intermediate splined shaft with the help of fork shifter and also is in
mesh with the gear on the lay shaft.
• Teeth denting on the Constant Mesh (CM) gear and Z-38 & Z-24
gear.
COLLAR BEND OF GEAR
Collar bend is only due to one reason
i.e. punching the code on the collar of
the gear.
The thickness of the collar is less , due
to which its bending stress is less.
When the punching machine punches
the code on the collar of the gear with
the pressure or stress mode than that
of bending stress of the collar , as a
result collar bends.
The shifting fork is put in the groove to provide the axially motion to the gear on the splined
intermediate shaft so to engage and disengage the gear . When this gear comes in mesh with
the gear on the lay shaft , it rotates but collar at the bended point does not provide the
sufficient space for the fork which restricts the motion and hence becomes the problem for
engaging and disengaging the gear.
Solution for Collar Bend :
• The punching should be done on
opposite side as shown –
• To avoid bending, punching should be
done at a point where thickness is
sufficient so that it can tolerate the
punching pressure.
• Another solution can be use of
special fixtures during punching of
the code which can support the collar
of the gear in groove.
DENTING OF GEAR TEETH
Denting is the indentation or bending of the gear teeth. Problem
arises from the dented teeth due to which gear box is disassembled.
• Gear box becomes noisy
• Gear box gives vibration

Cause of teeth denting :

• Mishandling
• Wrong usage of gear lever
REMEDY FOR DENTED TEETH :-
• The problem of gear box rejection
can be decreased significantly if
mishandling at various stages is
minimized.
• Using polymer cladding on gear
racks to save internal teeth from
deformation.
CORRECTED METHOD
• During heat treatment , placing
gears in improved way as shown.
 DATA OF REJECTED GEARS AFTER REMEDIAL MEASURES :

Gear Z-38 Rejected due

To collar bend
 CONCLUSION :

• Before implementation , the rejection of gear box was 2.276 %

• After remedial measure , the rejection due to above problems is

controlled to 1.048 %
 .

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THANK
YOU