International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 04 | May -2017
p-ISSN: 2395-0072
www.irjet.net
Experimental Analysis and Statistical Optimization of Effect of Heat Treatment Distortion in DIP Variation in an Idler Gear Shahade Ankit1, S. S. Sarnobat2, Uday Sankar Y3 1Department of Production Engineering (S/W), D.Y. Patil College of Engineering Pune, Maharashtra, India 2 Senior Professor, Department of Production Engineering(S/W), D.Y. Patil College of Engineering Pune, Maharashtra, India . 3 Senior Manager-Business Excellence & HR, Mahindra Gears and Transmission Pvt. Ltd. Chakan, Pune, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract – “Experimental Analysis And statistical
1.1 Problem Definition
Optimization of Effect Of heat Treatment Distortion on DIP Variation in an Idler Gear” The Objective of the Project is to reduce the rejection in gear having internal teeth and also reduce the scrap cost. This problem identified in Heat Treatment after the complete analysis of processes carried in both Before Heat Treatment and After Heat Treatment. Conducted the experiment and measured the variation in DIP. This is done by analyzing the Effect on Heat Treatment Distortion on DIP. Using the DIP readings, checking the effect and response design of experiment plan is introduce. Statistically analyzing responses of changed parameters are observed and depending on it, optimized changes in parameters are introduced.
During final inspection it is found that some parts on reverse idler gear are distorted in DIP. Distortion is measure cause of rejection. It was also found that distortion problem mainly occurs in specific lot. As the cost of one part is approximately Rs. 178, it is essential to find out the root cause and eliminate it. On analyzing the last six months data it is observed that 32% of rejection of this part is due to variation in DIP beyond its specification 1.2 Cost Of Poor Quality (COPQ) Cost Of Poor Quality per year considering maximum rejection in September is Rs. 1,62,336 2.0 Current Procedure:
Key Words: Process Capability, Gemba Observation, Stress Relieving, Change in Time and Temperature.
The actual parameters to be maintained during the heat treatment process, various controlling and checking parameters are mentioned in detail.
1.0 INTRODUCTION A Reverse Drive Gear, as shown in fig, of material 20MnCr5 alloy steel, has to undergo Heat Treatment of carburizing, the effective case depth required is minimum 0.35mm and maximum 0.5mm and surface hardness of 680-780 HV. The heating treatment process in conducted in seal quenched furnace, where both heating and quenching is done. This component detected distortion in DIP after Heat treatment crosses the permissible limit. This experiment is conducted to know the amount of distortion, to find out the probable causes and to take corrective action to control distortion.
Table -1: Process Cycle Processes with temperature, time and Carbon percentage Process Cycle Carburizing
Diffusion
Hardening
Tempering
Oil Quenching
Temperature (0C)
Time (Minutes)
Carbon Percent
100
1.00%
930
930
50
840
30
160
120
100
30
Fig 1.0 Idler Gear.
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