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INTRODUCTION
Hardening uses heat and rapid cooling (quenching) to increase the hardness, strength and/or
durability of steel. Heating steel or iron above their upper critical temperatures modifies the
crystal structure of the metal to a form called Austenite. With this atomic arrangement the carbon
can then freely migrate to a new location. When hardening, the aim is to quickly quench the
Austenite, thus trapping the carbon atoms in their new positions in the crystalline structure. The
transformed structure, called Martensite, is extremely hard. In addition, hardening creates
important internal residual stresses that can be either beneficial or disadvantageous. Depending
on requirements, tempering can be carried out after the induction hardening process.
With induction hardening, only the material in the heating zone is heated. Theres no need to
treat the whole mass of the component, thus saving energy. The hardening result depends upon a
complex interaction of process parameters such as coil and quench design, material analysis,
component geometry, heating frequency and power and quenching cycles. At EFD Induction we
have all the expertise required in electromagnetism, power electronics, metallurgy and induction
hardening process setup. Induction has been developing induction-heating solutions for more
than 50 years. Today, were the worlds largest induction hardening equipment maker, with
manufacturing plants, R&D centers and sales companies around the world. Our strength is
complete, tailored systems. We usually start in the lab, with materials analysis and computerized
simulation of various solutions. We also look at coil design, and determine which quenching,
loading/unloading and control systems best suit your needs. And of course, we dont consider our
job done until your systems and your operators are up and running 100%.
Hard-line is our complete range of heat treatment systems from vertical, horizontal, rotary table
and center less systems to customized, one-off solutions. In fact, custom-engineered solutions
account for more than half of all the hardening systems we deliver.
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HISTORY
GKN SINTER METAL is a British multinational automotive and aerospace components
company headquartered in Redditch, Worcestershire. The company was formerly known as
Guest, Keen and Nettlefolds and can trace its origins back to 1759 and the birth of the Industrial
Revolution.GKN is listed on the London Stock Exchange and is a constituent of the FTSE 100
Index. Dowlais Ironworks by George Childs (1840) The origins of GKN lie in the founding of
the Dowlais Ironworks in the village of Dowlais, Merthyr Tydfil, Wales, by Thomas Lewis and
Isaac Wilkinson. John Guest was appointed manager of the works in 1767, having moved from
SIDDHANT COLLEGE OF ENGINEERING,PUNE
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Aero structures
Engine Products
Propulsion Systems
2. GKN Driveline
Driveshaft
Freight Services
3. Auto structures
4. Power Management
Struma
Sinter Metals
Hoeganaes
References
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OPERATIONS
Hydrogen Storage
Hydrogen is emerging as an important energy vector and as a true zero-emission fuel if produced
with renewable energy.GKN is developing an innovative hydrogen storage technology on
industrial scale. In this technology, hydrogen is stored with superior volumetric density and low
pressure. Special metal composites store hydrogen as metal hydrides like in a sponge, making
this technology very safe and providing a low storage footprint.
Technology & Innovation
Our people are driving innovation. We have a vision of whats to come advanced thinking
increased capacity and design freedom. We spark life changing technologies, such as additive
manufacturing, high performance gears and soft magnetic composites. In a process driven
business powered by innovation we are a one-stop solution provider.
High Performance Gears
As development partner of the automotive industry we are producing the widest range of sintered
high performance gears from metal powder worldwide. Our processes are environmental
friendly, producing safe and quit-running components with a long service life.
Soft Magnetic Composites (SMC)
SMC enables entirely new approaches in electric motor design such as axial or transverse flux
motors. By using PM technology, the limits in torque and power density can be expanded, thanks
to an increased freedom in part design and reduction of manufacturing costs.
Design for Powder Metallurgy
The powder metal industry, for the most part, has historically operated in a build to design
environment, because engineers often work sequentially: first a design is completed, and then a
manufacturing process is sought. This method inhibits product optimization by overlooking the
advantages that the collaborative Design for PM approach delivers
Powder To Part: Material Manufacture
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Overview
Clutch hubs are high strength products that are attached to the clutch plate and used to transmit
engine output torque into the transmission. PM has proven to be an ideal and competitive
solution for this application due to a combination of net shape capability and excellent material
performance.
Application Details
Manual transmissions
Automotive and light truck
Advantages
Material: Steel
Process: Conventional PM
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Overview
One way clutches (OWC) are a key component of all automatic transmissions. PMs design
freedom combined with dimensional precision, and high performance materials facilitated the
development of new OWC systems that are more easily integrated into compact and efficient
transmission designs.
GKN is the market leader for PM OWCs with an established track record of delivering
optimized and competitive solutions for many customers and applications.
Application Details
Advantages
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Material: Steel
Process: Conventional PM
Overview
Planetary carriers are a key component of automatic transmissions. As the demand increased for
more fuel efficient vehicles with transmissions with more forward speeds, planetary carriers
became more complex and also began to serve multiple functions. PM technology has delivered
an essential solution by facilitating the integration of carrier housings with one way clutches,
hydraulic pressure systems and clutch backing plates resulting in unprecedented savings in
weight, space, and cost vs. competing technologies.
Application Details
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Advantages
Material: Steel
Process: Conventional PM
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4. SYNCHRONIZER HUBS
Overview
Synchronizer Hubs are the core product for the shifting mechanism in all double clutch and
manual transmissions. PM has proven to be the premier solution for this component, and has
facilitated improvements in performance while also reducing weight. GKN has a proven track
record of developing optimized and competitive solutions for many different customers and
applications on a global basis.
Application Details
Advantages
Lightweight, optimized designs with integrated features to improve performance and lubricant
distribution
Excellent dimensional precision for improved shift feel
Minimal machining is required due to nearest to net shape capability
Materials matched to performance requirements
In-house fatigue performance testing
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Material: Steel
Process: Conventional PM
Fig:-Synchronizer Hubs
5. TURBINE HUBS
Overview
Automatic transmissions rely on a torque converter to engage and disengage engine power
without the need for a driver-operated clutch. The main part of a torque converter is a fluid
turbine which selectively transfers engine power into the transmission. A turbine hub is the
coupling that connects the engine to the torque converter. PM technology has proven to be an
highly competitive and high performance solution for many customers and applications.
Application Details
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Advantages
Material: Steel
Fig:-Turbine hub
6. INDUSTRIAL COMPONENTS
Bicycle Hub Transmission Bicycle Hub Transmission
Components for bicycles provide a great variety of applicability for Powder Metallurgy, for
example in gear hub components. PM can be implemented for all components that are exposed to
high stress.
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Materials
GKN Sinter Metals offers the broadest material selection in the industry to meet a wide range of
needs, including Aluminum, Alloy and Stainless Steel, Iron, Bronze, Brass, Composites and High
Temperature alloys.
Prototyping in AM
In a competitive environment, speed is a crucial enabler - getting your solution to the market first
is a clear advantage. GKN's additive manufacturing capabilities are allowing us and our partners
to develop products more rapidly.
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LITERATURE SURVEY
1. A Critical Review On Different Coil Configurations Used For Induction Heating System
By Tejas G. Patil1, Atul A. Patil2, Vijay H. Patil3 Department Of Mechanical
Engineering Godavari College Of Engineering, Jalgaon, India.
Induction heating system has a number of inherent benefits compared to
traditional heating systems due to a non-contact heating process. The main interesting
area of the induction heating process is the efficiency of the usage of energy, choice of
the plate material and different coil configurations based on application. Correctly
designed, manufactured and maintained induction coils are critical to the overall
efficiency of induction heating solutions. The important investment in induction heating
process is in highly qualified coil technicians and advanced coil design equipment and
got benefit by having coils that are customized to their specific needs and conditions, The
objective of the present work reviews different coil configurations used for the induction
heating Process which is based on application such as surface hardening, Casting,
Rolling, welding, Brazing, Bonding, Post Heating and Water Heating.
2. Development Of Induction Surface Hardening Process For Small Diameter Carbon Steel
By Specimens Daisuke Suzuki, Koji Yatsushiro, Seiji Shimizu (1), Yoshio Sugita (2),
Motoki Saito (3), Katsuhiko Kubota(1) Yamanashi Industrial Technology Center (2) Ys
Electronics Co., Ltd. (3) Asakawa Heat Treatment Co., Ltd. (4) Marushin Heat Treatment
Co., Ltd.
In case of induction hardening, the highly frequency generator make a shallow
hardened zone. Additionally, hardening for smaller diameter specimen is enabled. In this
study, the induction surface hardening process by the ultra high frequency generator of
2MHz, which had not used in the general conventional process, was developed. The
specimen (6mm in diameter) was hardened using our developed device, under various
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Department, DAV Institute of Engineering and Technology, Kabir Nagar, Jalandhar City,
Punjab 144 008, India bMechanical Engineering Department, National Institute of
Technology, Kurukshetra 136 119, India email: mechanical_amit@yahoo.com;
hsingh_nitk@rediffmail.com.
In this paper, an effective procedure of response surface methodology (RSM) has
been utilized for nding the optimal values of process parameters while induction
hardening of AISI 1040 under two different conditions of the material i.e., rolled and
normalized. Various process parameters, such as feed rate (speed at which the induction
coil moves, which is measured in mm/sec), current, dwell time (time after which heat
intensity starts to heat work piece in seconds) and gap between the work piece and
induction coil have been explored by experiments. Hardness at two different conditions
has been considered as performance characteristic. The experi- ment plan was based on
rotatable, central composite design (CCD). The experimental results showed that the
proposed mathematical models suggested could describe the performance indicators
within the limits of the factors being investigated. The obtained optimal process
parameters have been predicted and veried by conrma- tion experiments.
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8. AMIT KOHLI and HARI SINGH(4), In this paper, an effective procedure of response
surface methodology (RSM) has been utilized for finding the optimal values of process
parameters while
induction hardening of AISI 1040 under two different conditions of the material
i.e., rolled and normalized. Various process parameters, such as feed rate (speed at which
the induction coil moves, which is measured in mm/sec), current, dwell time (time after
which heat intensity starts to heat work piece in seconds) and gap between the work piece
and induction coil have been explored by experiments. Hardness at two different
conditions has been considered as performance characteristic. The experiment plan was
based on rotatable, central composite design (CCD). The experimental results showed
that the proposed mathematical models suggested could describe the performance
indicators within the limits of the factors being investigated. The obtained optimal
process parameters have been predicted and verified by confirmation experiments.
Microstructure and SEM (scanning electron microscope) analyses were also done for
justification of the work
The experimental investigations have shown that the effect of process parameters such as
feed rate, dwell time, current and gap between material and inductor coil on the hardness of AISI
1040 steel under two different conditions i.e., rolled and normalized during induction hardening.
The optimal values for hardness obtained were 56.4 HRC and 57.8 HRC respectively for rolled
and normalized condition at feed rate of 3.21 mm/s, dwell time 5 sec, current 135 Amperes and
gap between material and inductor coil 5.29 mm as optimum value of process parameters. The
results tabulated in table 5 show that experimental data and data obtained by regression equation
closely correlate each other which validate the regression equations developed. Hence it can be
concluded that for making shafts, axles or automobile components from medium carbon steel,
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10.
Dr. Zhichao (Charlie) Li[9], Contact fatigue and bending fatigue are two main failure
modes of steel gears, while surface pitting and spalling are two common contact fatigue
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33362-0k050-00
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34881
Part Name
Customer
Defect Details -
30/07/2015
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1.4 Objective
1. To Reduce Uneven Induction Hardening.
2. Case Depth 1 2mm observed 0.41/0 & 0.70/0mm.
3. Develop New Design of Jig & Fixture.
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Methodology
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Forming
Sizing
Machining
Washing
Washing
Induction
Hardening
( Stansol 80 )
( Stansol 80 )
100% Visual
Inspection
Dewatering
Packing
Dispatch
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b)Impact on part verified Play observed in locating fixture as it is not a rigid , fixture is being
tightened with alen key & having a threaded shaft. There is chances of abnormal Induction
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3. .Uneven gap between part & coil as Heating coil & part gap setting method inadequate
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fig:b) As per regular process gap of 0.9mm is being kept between part & coil. During simulation gap
increased by 0.8mm & 1.3mm than regular gap of 0.9mm. Parts observed at lower for case
depth for gap of 1.7 mm & observed NG for case depth ( Nill case depth ) for gap 2.2mm
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d) Operator set the fixture height & gap between part & coil with the help of setting master of
height more than 0.8mm than part boss height. The master is being placed on part locating
fixture & touches the coil to the top surface of master & by manual feeling he adjust the gap.
This cycle repeated for each station. Operator adjust the gap as per his experience & manual
feeling, there is no measurable method / system .Can be cause for Occurrence of defect.
However, gap setting by filler gauge is planned. New master is under manufacturing. This will
ensure further reduction in gap variation.
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Trial
Change point
details
Qty
Produced of Parts -
of Parts
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Coil Gap
( Trial
1
Cut Check
Hardness
Visually NG
in Presence 0.9mm
observed Less
.
CD Nill &
of TKAP
0.2mm
Team)
Gradual
Change to
Coil Gap to
Confirm
6
the defined
standard
for coil gap
( 0.9mm )is
0.9mm,
Changed to
1)
2)
3)
4)
5)
1.1mm
1.3mm
1.5mm
0.7mm
0.5mm
06 Nos
Detailed
Detailed
concluded that
Report
Report
Defined Standard,
Attached
Attached
Gap of 0.9mm is
below
below
correct or
not
Trail is Pending due
5
Tilting the
Coil
to dispatch urgencies.
result to be
Unable to spare
compared.
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Factor No. 9
Variation in Gap Between Part & Coil in Six station
WHY 1 Gap setting method inadequate
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Factor No. 11
Incorrect Checking Frequency
WHY 1 Only One part is being checked at First off & during shift for case depth & Hardness
which is not sufficient frequency to identify part to part & in process variation.
WHY 2 Checking Frequency Not defined correctly.
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Factor No. 10
Part Inspection Method Inadequate
WHY 1 Only One Section / Quarter Section of Part is being cut & checked for case depth &
Hardness which is not sufficient to identify within part variation.
WHY 2 Checking method not defined correctly in Control Plan
Root Cause Non Detection
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Factor No. 11
Incorrect Checking Frequency
WHY 1 Only One part is being checked at First off & during shift for case depth & Hardness
which is not sufficient frequency to identify part to part & in process variation.
WHY 2 Checking Frequency Not defined correctly.
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Factor No. 10
Part Inspection Method Inadequate
WHY 1 Only One Section / Quarter Section of Part is being cut & checked for case depth &
Hardness which is not sufficient to identify within part variation.
WHY 2 Checking method not defined correctly in Control Plan
Root Cause Non Detection
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Shedule :No
Actions
Target
Status
11/08/2015
In
Process
Toyota Part.
2
09/07/2015
Started
22/07/2015
In
Process
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07/07/2015
Started
07/07/2015
Started
04/07/2015
Started
03/07/2015
Started
03/07/2015
Started
22/07/2015
In
Process
100% inspection.
For Eddy current test proposal we have given the
ok and NG samples to Technofour .The trials shall
be taken on the coil and based on the trials they
will submit the quotation.
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PART DIAGRAM:-
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MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
Time in minutes
Clamp stock
Three jaw
M/c
Cutting
Tools
Tools
Lathe
Time
Total
Time Time
20
20
10
10
chuck
Three jaw
to total length
chuck
Lathe
82mm
Facing
Vernier
tool
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Turning OD
Turning
53.5 mm through
tool
15
20
Vernier
20
20
Vernier
20
20
length
4.
5.
StepTurning OD
Centers
to 14.70mm
supports &
through length 7
carrier
StepTurning OD
Centers
to 38.5mm
supports &
through length
carrier
Lathe
Turning
tool
Lathe
Turning
tool
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SHEET 2:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
1
2.
Time in minutes
Groving OD to
Centers
7mm through
supports &
length 9
carrier
Chamfring
Centers
2.5mm
supports &
M/c
Cutting
Tools
Tools
Lathe
Turning
Time
Total
Time Time
Vernier
20
20
Vernier
20
20
tool
Lathe
Turning
tool
carrier
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SHEET NO 3:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
1
2.
Time in minutes
StepTurning OD
Centers
to 28mm
supports &
through length12
carrier
Turning OD
Centers
18.5 mm through
supports &
length 50mm
carrier
M/c
Cutting
Tools
Tools
Lathe
Turning
Time
Total
Time Time
Vernier
22
22
Vernier
30
30
tool
Lathe
Turning
tool
SHEET NO 4:-
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MATERIAL SPECIFICATION : MS
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
Time in minutes
Clamp stock
M/c
Cutting
Tools
Tools
Three jaw
Drill
chuck
m/c
Drilling 4 holes 5
Centers
Drill
Drilling
mm
supports &
m/c
tool
Time
Total
Time Time
20
20
Vernier
10
10
Vernier
30
30
20
20
carrier
3
Centers
Drill
Turning
2mm
supports &
m/c
tool
carrier
4
Clamp stock
Three jaw
Lathe
chuck
SHEET NO 5:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100
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Description of
Tools
Operation
Jigs &
Fixture
1
2.
Time in minutes
StepTurning OD
Centers
to 28mm
supports &
through length12
carrier
Turning OD
Centers
18.5 mm through
supports &
length 50mm
carrier
M/c
Cutting
Tools
Tools
Lathe
Turning
Time
Total
Time Time
Vernier
22
22
Vernier
30
30
tool
Lathe
Turning
tool
SHEET NO 6:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 75X 90
Sr.
No
Description of
Tools
Time in minutes
Operation
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Clamp stock
Three jaw
M/c
Cutting
Tools
Tools
Lathe
Time
Total
Time Time
20
20
10
10
15
20
Vernier
20
20
Vernier
20
20
chuck
2
Three jaw
to total length
chuck
Lathe
Vernier
tool
85mm
3
Facing
Turning OD 70
Turning
mm through
tool
length
4.
5.
StepTurning OD
Centers
to 50mm
supports &
through length 60
carrier
StepTurning OD
Centers
to 28 mm
supports &
through length
carrier
Lathe
Turning
tool
Lathe
Turning
tool
60mm
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SHEET NO 7:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 60X 100
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
1
Time in minutes
Clamp stock
M/c
Cutting
Tools
Tools
Three jaw
Drill
chuck
m/c
Time
20
Total
Time Time
-
20
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Drilling holes 18
Drill
Drilling
m/c
tool
Centers
Drill
Boring
supports &
m/c
tool
mm
Boring 0.5mm
Vernier
10
10
Vernier
carrier
4
Chamfring
Three jaw
Lathe
chuck
SHEET NO 8:-
MATERIAL SPECIFICATION : MS
RAW MATERIAL SIZE: 70X90
Sr.
No
Description of
Tools
Operation
Jigs &
Fixture
1
Time in minutes
Centers
2mm
supports &
M/c
Cutting
Tools
Tools
Lathe
Turning
Time
-
Total
Time Time
2
tool
carrier
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MODEL NO 4:-BOLT
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MODEL NO 5:-ASSEMBLY
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COST ESTIMATIONS:-
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CONCLUSSION:-
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REFERENCE
1.Amit kohli and Hari Singh (Received 2 Jan., 2010, Accepted 15 Feb., 2010) Optimizing mean
effective case depth of induction hardened parts(rolled condition) using response surface
methodology.
2. B. Kosec , B. Karpe , M. Licen and G. Kosec (Received 07.01.2010; published in revised form
01.04.2010) Inductive heating and quenching of planetary shafts.
3. Stanley Zinn and S. L. Semiatin -Coil design and fabrication: basic design and modifications.
4. P. G. Kochure and K. N. Nandurkar [Issue 2 (July-Aug 2012)] Mathematical modeling for
selection of process parameters in induction hardening of EN8 D steel.
5. V. Rudnev, D. Loveless, R. Cook and M. Black- Induction Hardening of Gears: a Review
6. Mert Onan, Kasim Baynal, H.Ibrahim Unal and Furkan Katre (November 9-15, 2012)
Optimization of Induction hardened AISI 1040 Steel by experimental Design Method and
Material Characterization Analysis.
7.Shailesh S. Pachbhai and Laukik P. Raut(Feb-Mar 2014)A Review on Design of Fixtures.
8.Tejas G. Patil, Atul A. Patil, Vijay H. Patil A Critical review on different coil configurations
used for induction heating system.
9. Habib Hammi, Noureddine Barka and Abderrazak El Ouafi (7 jan 2015)Effects of Induction
heating process parameters on hardness profile of 4340 steel bearing shoulder using 2D
axisymmetric model
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