DEPARTMENT :- MAINTENANCETRAINEE NAME :- TUSHAR BANSAL

TRAINING PERIOD :- JUNE 2015- DEC 2015

MENTOR NAME :- Mr. VIJAY SINGH

INDUSTRIAL PROJECT TRAINING

PERSONEL INFORMATIONNAME TUSHAR BANSAL

DATE OF BIRTH : 26 Oct 1994

QUALIFICATION : Pursuing B.Tech in Electrical Engg. From YMCA University Of Science & Technology.

COMPANY NAME : GKN DRIVELINE INDIA LTD

DEPARTMENT : MAINTENANCE

DESIGNATION : Project Trainee

CERTIFICATE

This is to certify that the project report titled PRODUCTION OF DRIVESHAFT UNITS Submitted by TUSHAR BANSAL in the partial fulfillment of the requirements of GKN Driveline (India) Ltd, as part of the degree of Bachelor of Technology in ELECTRICAL ENGINEERING from YMCA University Of Science & Technology is a record of bonafide work carried out under our supervision and has not been submitted anywhere else for any other purpose.

Date of establishment : 1st August, 1986

Date of Commercial Production : April, 1989

Plant Locations : Faridabad,Dharuhera,Chennai Pune

GKN Equity Holding : 1988 - 40%

1995 - 51%

2008 - 99.3%

GDI- Information Summary GDI- Information Summary

GKN Driveline – a global leader in automotive

Sales in 2007 of £ 4.3 bn

World No 1 CVJ producer - 42% of work market share

Global supplier to all major car manufacturers

Supply all components in the driveline

Widest range of driveline components• CVJ sideshafts• Propshafts• Torque management devices• Geared components

21,000 people

49 manufacturing locations

3 regions – 31 countries

Driveline• World No 1World No 1 in production of constant velocity joints (CVJs) with 42% global market

share• Leading market positionLeading market position secured in Torque Systems

Powder Metallurgy• World leaderWorld leader in the production of powder parts with 16% market share and US No 1US No 1

in powder manufacture

Aerospace ServicesLeading supplier Leading supplier to aerospace industry - core structures supplier to Boeing Military Aircraft and Missile Systems GroupWorld No 1World No 1 independent supplier of composite structures

GKN – a global leader in automotive and aerospace

GDI LOCATIONS

Delhi

PUNE

Chennai

Faridabad

Oragadam

Dharuhera

GDI : Faridabad PlantGDI : Faridabad PlantOperations :Commenced operation on 13th April, 1989

Land area 40,000 sqm

(Built-up 8,000 sqm)

Manpower 357

GDI : Dharuhera PlantGDI : Dharuhera PlantOperations :Commenced operation on 14th January, 1997

Land area 68,800 sqm

(Built-up 4,500 sqm)

Manpower 302

GDI : Oragadam PlantGDI : Oragadam PlantOperations :

Commenced operation on Jan 2008

Land area 58000 sqm

(Built-up 6400 sqm)

Manpower 288

GDI CUSTOMERS & SALES PROFILE

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

INR

Mill

ion

3004506007509001050120013501500165018001950

000

v. s

ets

Value (INR) 1428 1419 1579 1846 2487 2882 3390 3825 4310 4950Volume (V.sets) 365 372 421 495 655 785 926 1102 1340 1590

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Economic Growth in Terms of Sales

Honda2%

Hyundai18%

OESP2%

Ford2%

FIAT0%

VW1%

TATA5%

Exp5%

GMI1%

M&M1%

Aftr MKT1%Spicer

1%

Maruti61%

4 4 5 8 11 1317 17 20

24

35

45

65

82

1 3 3 4 5 6 7 7 7 8 9 9 9 1116

18

0

10

20

30

40

50

60

70

80

9019

95

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

Car companies Car Applications

GDI Growing Complexity

Quality CertificationQuality Certification

Faridabad Plant & Corporate Office certified to ISO9002 Standards in January 1997.

Received QS9000 certification for all the Plants and Corporate Office in May 1998.

Received ISO14001 in August 2002.

Received TS 16949 (Edition 2) in November 2003.

Received OHSAS 18001 in February 2004.

My Project

Plant Overview & observation of various Electrical Faults.

Study of main child parts of Complete DRIVE SHAFT.

Tulip

AC-Cage

Do Outer Race

AC Inner Race

Shaft AC Outer Race

Do Inner Race

Step-01

DO-Cage

COMPLETE DRIVESHAFTAC/DO Outer Race

AC/DO Inner Race

AC/DO Cage

Shaft

Tulip

Tripod

Steel Balls

Rubber boots

PRODUCTS OF GKN DRIVELINE FARIDABAD

Step-02 Study of Manufacturing Operations for all components.

Finish Milling Rolling

Washing

Induction Hardening

TemperingID & Track Grinding OD Grinding

Taking Example of Outer Race(Getz)

Rough Milling

Crack Check

Safe Launch

Step-02 Study of process sheets for each Model in all components.

For Example,process sheet for Getz Outer Race in OD

Grinding Operation is

shown

BELL JOINT ASSEMBLY

1. FIXED OUTER RACE OPERATIONS

SOFT MILLING

SPLINE AND ROLLING

INDUCTION HARDENING(STEM AND MOUTH)

1(a) MILLING

In the milling operation,the machine makes Track&Inner diameter on the bell of proper size with the help of revolving cutter. The milling operation takes place in two stages.

Rough Milling.

Finish Milling.

TOOLS USED

Insert(Reviling cutter)

Collets(Pneumatic deice to hold the Work piece)

Locating block(Locate the work piece at its position)

Insert holder (To hold the cutter)

Rest pad(Locate the work piece at proper height relative to insert)

Locating and conveyor block (Install the component in the collets)

1.(B) ROLLING

Rolling is the forming process (Zero process i.e. no material is added or removed). This is the second operation in which spline and threads are to be made by rolling the stem of the component between two racks.

Firstly V-block holds the job and then takes the job in between a pair of thread rack and spline rack, which is fitted horizontally. Now it presses the job and moves in horizontal plane. In this way spline and threads are form on the component.

TOOLS USED :

V-blockLocator

Spline rack

Thread rack

RAKE SLIDE FITTED HORIZONTALLY

(C) SIMPLICITY WASHING

Washing is used to remove oil and grease. During the rolling operation of lubricating fluid is to provide lubrication and dissipation of heat during the process. For this purpose dematerialized water with detergent is used on the job to clean it. This operation is very important because for proper hardness of job i.e. in order to obtain desired hardness or property, it is necessary to remove oil, grease and any other foreign particles from the job before hardening.

(D) INDUCTION HARDENING

Induction hardening is the process in which we increase the hardness of the material without touching the work piece and the process is effective and fast.

INDUCTION HARDENING BASICS

RED HOT DUE TO RESISTANCE

An alternating current flows through a coil, creating magnetic field (the blue lines).Fig.1

Eddy current will be induced due to the high resistance of steel. Heat is generated due to which the component become cherry red. Induction is a no-contact heating method; at no time does the coil actually touch the work piece.

BASIC FORMULA

Induction Hardening is based on a formula:

H = I. R

Here ‘H’ denotes heat generated.

‘I’ denotes alternating current.

‘R’ denotes resistance.

STEM HARDENING MOUTH HARDENING

Side View

ABOUT EFD MACHINEIn GKN Driveline, EFD induction hardening machine is being used for this process. It is a process in which a specific depth of hardness can be attained. Basically, this is a process which is mainly used for mass production only. It is a safe, clean and easy method. In this process the machine lift the job from conveyor belt place it in the holder. Then in stem &mouth current is induced through the inductor & the temperature of job rises above the critical temperature the job is the suddenly quenched by using a solution of water & aqua quench. In this process a certain depth of hardening is achieved.

(E) MAGNA TEST

It is a computerized process used to find the hardness the job by using sensors. In this process three zones are specified by the engineer as shown below one is in between grey lines which is safe zone if the computer shows that the hardness of the component lies in this region means that the component is properly hardened. Second zone lies between grey and yellow line which is a moderate zone if hardness lies in this zone means the component is under heated and if it lies in between grey and red lines means the component is overheated therefore it is called dangerous zone . If the job does not lie in between this range, the machine will stop until part is scraped.

(f) MARKINGMarking is done to identify the component date, shift, customer and cell the objective of marking is to keep the record of part

Punching is used to keep the record of the part, which is used to track the company name, code, date, shift and company in which it will dispatch.

GDIL QC 17 11 12 A MUL 2

 

 

MFGCODE DATE SHIFT CUSTOMER CELL-2

(G) TEMPERING It is a heat treatment process in which the component is heated to a certain temperature and cools it slowly in the presence of air. During induction hardening a lot of stresses is built up in the job. Now it is required to relieve of these stresses as they lead to pre-mature failure. For this the job is heated to a temperature of about 180 degree C for a period of two hours. This refines the grain structure of the job.

1ST ZONE TEMPERATURE = 180±5 DEG.

2nd ZONE TEMPERATURE = 200±5 DEG.

(H) OD GRINDINGThere are two process of OD finishing. These operations are performed on the requirement of surface finish.

Grinding

Turning

GRINDING

In this operation a small amount of material is removed from the job so that it become smooth and finish and offer minimum friction with mating parts this operation is very necessary in order to remove friction. The surface of the job should be smooth and finished.

Two type of grinding is done on the fixed outer race or bell on grinding machine.

(I) O.D GRINDING MACHINE-1

This machine is used to grind the outer surface of the bell the outer surface of the bell is grinded to make it shinning and smooth so that it offers minimum friction with mating part. The grinding wheel used is of the same profile as that of fixed outer race.

(II) O.D TURNING This machine is used to grind the outer surface of the bell. The outer surface of the bell is turned to make it shinning and smooth so that it offers minimum friction with mating part.

TOOL USED

Tool Holder

Inserts

Locator

Dead Centre

(i) TRACK AND I.D TURNING MACHINEThis is the final machining operation. During the induction hardening and tempering the surface of mouth become rough and geometry also disturb.

This machine operates on the inner diameter and tracks of the bell’s mouth. The inner diameter and track surface of bell is turned to make it shinning and smooth so that it offers less friction with mating part.

TOOL USED

Tool Holder

Orientation Unit

Collets

Rest Pad

ID Turning Inserts

Track Turning Inserts

(J) OIL WASHING

Washing is used to remove cutting oil. For this purpose dematerialized water is poured on the job to clean it. This operation is very important for the crack detection.

(K) CRACK DETECTION AND OILINGCrack check is done to find any crack in the finished job. It is based on the principle of PIEZO-ELECTRICTY. Firstly the job is magnetized and dipped in the solution of MAGNA FLUX. Then job is passed through the filtered ULTRA VOILET RAYS. This shows the cracks on the job. The job having cracks is rejected. The next step is to demagnetize the component.

After the demagnetization the next process is oiling the component to prevent it from rusting during transportation.

BELL ASSEMBLY

Before assembly

After assembly

Thank You