Presentation on Six Month

Industrial Training in
HERO MOTORS

COMPANY INFO

Hero Motors Ltd. develop, manufacture and supply

components and assemblies to automotive and white
good to OEM industries. Company is committed to
design, implement & comply with Quality
Management Systems and ensure its effectiveness
and continual improvement through active
participation of all employees

roup Evolution
Group has evolved with
reliable partnerships with technology Partners, Dealers, Suppliers,
Employees,
Institutions and Investors.
Auto components ancillaries
started as suppliers of major
components to the three Group
OEM. Well established base
with technology and cost
leadership

Manufacture of
cycle part and
later on full
cycles
1956

Manufacture of
mopeds tied up with
Steyr Daimler Puch in
1988 when Hero
Motors was setup
1978

JV up with Honda in 1983

Hero Honda set up to start of
motorcycle manufacture
1983

Milestones
1956- Set up as a bicycle Company- Hero Cycles Limited
1978- Moped manufacturing Company- Majestic Auto Limited was formed
1988- Hero Puch- Mini Motorcycle was Introduced by Hero Motors
1993- Became Indias largest Exporter of 2- wheeler.
2003- Entered into agreements with Rotax for Engine & Part Development &
plant up- gradation
2006- Ferrous Casting plant at Manesar, Haryana begins Operation.
2007- Formation of JV Entity Munjal Kiriu Industries Pvt Ltd in technical
collaboration with Sumitomo Kiriu Corporation, Japan for Manufacturing of
automotive brake discs, brake drums and knuckles.
2010- Formation of JV with ZF Lemforder of Germany for Chassis Systems.
2010- Entered technical assistance agreement with Magna Steyr India for
design and development of global recreation transmission.
2012 Tie up with Mariott Group of luxury hotels for Munjal Hospitality

Diversified Businesses

Assimilated Technology
High Growth

Hero Motors Next Level

Learnings over the past years, has got us from

Formative Years to the Next Level

1.

BRP

Shop floor best practices

2.

BMW

Deep Supplier improvement

integration
3.
4.

Honda
Sumitomo

5.

Suzuki

6.

ZF

Lean manufacturing from the Top

Organization Development

Ready for the scale up

Hero Motors Transmission

Location
: Ghaziabad
Vertical
Snapshot
State-of-art equipment, German and Japanese technology for Gear manufacturing.
Precision technologies like teeth honing and teeth grinding are available.
Technology assistance agreement with Magna Steyr India
Application Engineering Centre in Graz, Austria
Product Range
Gearbox
Gears & Shaft Assemblies
Engine Gears
Sprocket Assemblies
Balance Shaft
New Product Development
Gearbox for motorcycles,
Transaxles for electric vehicles,
Innovative design to cost solutions for
Automated Manual Transmissions (AMT)
Double Clutch Transmissions (DCT)
Continuously Variable Transmissions (CVT) for passenger cars
Leading
Customers :

Hero Motors - Sheet Metal

Location
: Ghaziabad
Vertical
Snapshot

Equipped with new generation units, the Sheet Metal Unit manufactures and supplies
sheet metal parts to Hero Honda Motors Ltd.
The Unit meets demand for Swing Arm, Chain Covers and Stands.
Sheet Metals Press Shop has a capacity to produce 2 million chain covers per year,
while Welding Facility, which has 100 MIG welding machines, has a capacity to
manufacture more than 6,000 Swing arms per day.
The Units Paint shop is equipped with Metal Paint shop, powder Coating Facility and
Plastic Paint shop.
Product Range
Swing Arm
Chain Case
Cylinder Block
Stands

Leading
Customers :

DOL
Status

HISTORY OF GEARS
Gears are used for transmission of power or
motion . A gear is defined as a wheel with teeth cut
on its rim. Gear acts and operate in pairs . engaging
or meshing teeth of each other , in a pair one acts as
a driver and other acts as a follower .
Gears are used when the distance between
driving shafts and driven shafts is very small . it is
possible to drive shafts that are parallel
intersecting, or neither intersecting .many different
type of gears are used and their selection depends
on many factors , such as the relative position of the
two shafts , the power to be transmitted , in running
condition

COMMONLY USED FORMS

a. Involute
The involute tooth is derived from the traces
of the point on a straight line , which rolls without
slipping around the base circle . the involute
system has a standard pressure angle which is
20 degree and 14.5 degree.
The involute gear are also called as straight
tooth gear or spur gear and mainly used for
general purpose in precision engineering due to
some advantages.

COMMONLY USED FORMS

b. Cycloidal
The cycloidal tooth is derived from the curve
which is the locus of the point on a circle rolling on the
pitch circle of the gear . the cycloidal system the angle
varies from zero at pitch line to a maximum at the tips
of the teeth .In cycloidal system the pressure angle
varies from zero at pitch line to a maximum at the tips of
teeth.
The cycloidal gears are not generally used in
modern engineering , but used for some crude purposes
where heavy and impact loads comes on the machine.

TYPES OF GEARS

Working in Soft Section

Teeth are cut & finished in this section.
The blank pieces come from vendors & are worked upon
in this section.
Different types of gears & pinions are constructed in this
section.

BASICS OF HOBBING

GEAR HOBBING

Hobbing is the fastest and cheapest system to

produce gear (or every profile repeated regularly
in a cylindrical surface)

HOBBING
Hobbing is the machining process for making gears,
splines.
The teeth or splines are progressively cut into the
workpiece by a cutting tool called a hob.
It is most widely used gear cutting process for creating
spur & helical gears.

Working Condition

What is a Hob Cutter?

Hob main dimensions, diameter and
length, depend on many factors

L
Characteristic of the gear (module, diameter, ..)
Characteristic of the hobbing machine
Type of production

What is a Hob Cutter?

Hob
is
basically
a
worm.
The rotation during hobbing is like of a couple of worm gear
and worm.

Start = the profile turns around base cyclinder-axes, following

a specific helix with a specific pitch

Hob charateristic
The hob is charaterized first by the overall
dimension
(diameter,
length,
bore
diameter) and by the following elements:

Module
Pressure angle
Number of starts
Type of profile

BASIC OF GEAR SHAVING

Gear Shaving
Gear shaving is the
most common and the
cheapest
finishing
system of the cylindrical
gear.
With this presentation we
will
give
the
basic
information about the
shaving process.

Gear Shaving
Advantage of shaving against grinding

Easy application of involute profile and lead modification

Short cycle time
Possibility to finish gears close to shoulders
Reasonable set-up time
Low tool cost per piece
Low investment for the purchase of a shaving machine
Easy procurement of tools
Easy automatization

Disadvantage of shaving against grinding

Shaving process must be applied before heat treatment.
Heat treatment distortions result in errors.
The shaving result is highly dependent by the qualityof the workpiece.
Occasionally impossible to use the shaving tool on gears with a small
number of teeth.

BASIC OF GEAR TEETH GRINDING

GEAR GRINDING TECHNOLOGY

HISTORY OF GEAR GRINDING

In recent years some extremely innovative gear grinding
machines have come into the market both in terms of
how they are constructed and of how they operate.
It is a well-known fact that the two main gear grinding
techniques used today are grinding using a form wheel
(the profile grinding method) and grinding using a worm
wheel (the continuous generating grinding method).
There are advantages and disadvantages with both of
these methods which may influence production times,
accuracy, surface quality of the ground tooth and so on.
By this presentation we will give the basic information
about gear grinding operation

The most established grinding methods are:

Continuous
generating
grinding with a worm
wheel

Profile grinding with

a form wheel

Notes on the continuous generating

grinding method
The worm wheel can either be ceramic or CBN with a diameter
that ranges from about 100 to about 350 mm.
The wheel may have more than one start just like a hob. The
kinematics are the same as in hobbing. This method is suitable
for medium-large batch production.
In general grinding times are shorter compared to form grinding
if grinding gears with Z>15 but longer with Z<15.
It is only possible to grind profiles that are obtainable by
generation.

VIEW OF GRINDING BY WORM WHEEL

In worm grinding method
Kinematics is the same as working with hobs

X = radial feed
Z = axial traslation
Y = Shifting

With form method its possible to grind

also internal gears

Hard finishing External Honing

Kinematics is same
to shaving

Good surface
Short cycle time
Easy to find tools
Easy to modify profile and
helix

Internal honing

Good accuracy
Short cycle time
High cost of the tool
Every gear needs a special tool

SHAPING
It is another machining process for creating teeth on a
gear using cutter.
It is a gear cutting process is in form of spur/helical
gears.
Internal gears can be cut with this method as well.

Operation Principle

Parts manufactured by Shaping

HEAT TREATMENT
Is the controlled heating and cooling of
metals to alter their physical and
mechanical properties without changing
the product shape.

Pre Washing

Select the Timer for Sparying of Charge as 30 Minutes.

Check Skimmer Motor Working.
Load the charge for Pre Washing.
Monitor the Washing process through Temperature Controllers & Timers & record in Process Control sheet

Spraying

Temp

15Min.

Spraying

15Min.

Time

Drying

0Min.

Pre Heating

Set SP-1 as 450oC in Furnace Main Temperature Controller.

Set Soaking time as 60 Minutes on Timer & reset the Heaters.
Monitor the Pre Heating process through Temperature Controllers & Timers & record in
Process Control sheet.
After completion of Pre Heat Shift the Material to Sealed Quench Furnace for Next Process

Temp

Time

Sealed Quench Furnace

Various Stages in SQF:Carburizing

Diffusion
Hardening
Quenching
Oil Dripping

Sealed Quench Furnace Thermal Mapping & Surface Carbon

Sample
No

C%

Sample
No

C%

0.725

0.715

0.709

0.697

0.703

0.694

0.692

0.688

0.718

0.683

0.734

0.707

0.696

0.665

0.685

0.683

0.693

0.697

Variation

0.049

Variation

0.050

Post Washing

Steps in Post Washing:Select the Timer for Plunging, Bottom Resting, Spray, Hot Drying, Blower &
Skimming of Charge as 10 Minutes Each.
Check Skimmer Motor Working.
Load the charge for Post Washing.
Monitor the Washing process through Temperature Controllers & Timers &
record in Process Control Sheet

Tempering

Steps involved in Tempering:-

Inspection lab

Inspection Lab

Shot Blasting

PROJECT UNDDERTAKEN
SPAN SIZE VARIATION IN
PRIMARY GEAR K5X

Problem Definition : Part No - 8530239 & 293

Localized Mass on
Part

Part No : 8530239

Part No : 8530293
Due to Localized Mass on Part the Overall SPAN variation was
non uniform & up to 70 , due to this meeting final dimension
was difficult.

Reasons for variation in Case Depth

Variation in Case Depth on Mass Side and
Opposite side.
Carbon pickup rate is high on the mass side
in comparison to opposite side as heat
retention is more on the mass area.
Core hardness more than specification.
Hardenability band of 20MnCrS5 steel grade
is J5mm
=35-45HRC. Hence Core hardness
can be achieved any value in between this
band

Understanding of Process Flow - 8530239 &

293
Blank
Receipt

Hobbing

Teeth
Honning

Teeth
Grinding

Final
Inspection

BHT
OK

Packing

Hard Turning

Heat
Treatment

AHT
NG

Despatch

Step for
Improvement
Step :
1
Loading Pattern
Changed to keep
the Mass area on
Top.

Step for
Improvement
Step : 2
Hardening Temperature reduced
from 840 OC to 820 OC.

Step : 3
Quench Oil Temperature raised
from 110 OC to 130 O C.

Step : 4
Oil Agitation changed from
Continuous Agitation to Step Agitation.

Improvement Area
Before Modification
Before

After Modification
After

Results