gear testing

PUNJAB BEVEL GEARS

INTRODUCTION

SAHIBABADUTTAR PRADESH

4 PLANTS*

LUDHIANAPUNJAB

SITARGANJ**UTTARAKHAND

GROUP COMPANIES

DIFFERENTIAL & TRANSMISSIONGEARS andDIFFERENTIAL CAGE

FORGING MACHININGAXLE SHAFT

DIFFERENTIAL & TRANSMISSIONGEARS

*There are 4 manufacturing units located within 500 metres in Sahibabad and share common resources of Metrology and Metallurgy.

**Under Commissioning

•STARTED OPERATIONS IN 1979

•MANUFACTURES MORE THAN 2000 DIFFERENT TYPE OF GEARS

•LEADING MANUFACTURER, SUPPLIER AND EXPORTER OF AUTOMOTIVE PARTS

•CATERS TO INDUSTRIES LIKE COMMERCIAL VEHICLE, AGRICULTURAL TRACTORS, PASSENGER CAR, THREE WHEELER & CONSTRUCTION EQUIPMENT

INTRODUCTION…..Contd.

OUR COMPETITIVENESS LIES IN THE FACT THAT WE ARE :

• COST COMPETITIVE,

• QUALITY CONSCIOUS,

• HAVING TRACK RECORD OF ON TIME DELIVERY

• HAVING CAPABILITY TO DEVELOP NEW PRODUCTS IN A SHORTER PERIOD

AND

INTRODUCTION…..Contd.

• FINANCIALLY SOUND

• HAVING ASSURANCES FROM FINANCIAL INSTITUTIONS FOR SUPPORT IN THE ONGOING AND FUTURE EXPANSIONS

• HAVING VERY SOUND HR POLICIES WITH ALMOST NIL EMPLOYEE TURNOVER

• THE AVERAGE AGE OF EMPLOYEES IS 40 YEARS

•HAVING 100% CAPTIVE POWER BACK UP

• AN ISO/TS 16949: 2002 CERTIFIED COMPANY

INTRODUCTION…..Contd.

PRODUCT RANGECROWN WHEEL & PINION (Gleason & Oerlikon System)

ST. BEVEL GEARS & PINIONS (Gleason Coniflex System)TRANSMISSION GEARS

(Spur, Helical)DIFFERENTIAL CAGE

AXLE SHAFTS

FORGINGS

MACHINED FORGINGS

TOTAL SALES (Mio Rs)

404

547

764

1116

971

0

200

400

600

800

1000

1200

FY05

FY06

FY07

FY08

FY09

TOTAL SALES (Mio $)

10.1

13.7

19.1

27.9

24.3

0

5

10

15

20

25

30

FY05

FY06

FY07

FY08

FY09

SEGMENT WISE SALES FY 09

OEM (DOM)32%

OTHERS6%

EXPORT62%

OEM (DOM)EXPORTOTHERS

CAPACITY INSTALLED

Sl.No. Product Annual* New Capacity Utilization*

Capacity under of existing

installation capacity

1. Crown Wheel & Pinion 420,000 Sets 120,000 sets 70%

2. Straight Bevel Gears 720,000 Nos. 300,000 nos 70%

3. Transmission Gears 1,200,000 Nos. 400,000 nos 70%

4. Axle Shafts 60,000 Nos. 60,000 nos 25%

5. Forgings 12,000 MT -- 40%

* On 2 Shift Basis

TYPE SPIRAL/

HYPOIDS

STRAIGHT

BEVEL

SPEED

GEAR TRANS. SHAFT

MAX. SIZE (DIA) MM 500216(10:1)

152(1:1) 400 80

MAX. FACE WIDTH/L 76 50.80 400 750

MAX. MODULE (mm) 12.70 8.50 8.00 8.00

ACCURACY DIN

CLASS 8-9

DIN

CLASS 8-9

DIN

CLASS 8-9

DIN

CLASS 8-9

CAPABILITIES - GEARS

CAPABILITIES - FORGINGS

• Weight 0.5 Kg to 50 Kgs

• Round Forging Min. Dia 80 mmMax. Dia 500 mm

• Shaft Forgings Length 1200 mmFlange Dia 325 mm

SAHIBABAD LUDHIANA SITARGANJ

TOTAL AREA 500,600 152,500 183,140

COVERED AREA 179,390 46,000 95,200

GENERAL OFFICE AREA

5,420 5,000 11,600

PLANT AREA IN SQ. FT

Sahibabad LudhianaSitarganj (Planned)

Hourly 435 65 100

Supervisory 47 07 12

Manager 13 01 02

Total 495 73 114

MANPOWER

PUNJAB BEVEL GEARS LIMITED ( AN ISO/TS 16949: 2002 COMPANY)

(Excluding Product Design)

RECOGNISED STAR EXPORT HOUSE AWARDED SILVER SHIELD FOR EXPORT

PERFORMANCE DURING 2005-06 BY EEPC

CERTIFICATION

CNC Turning Lathes 22 Nos.

Vertical Machining Center 03 Nos.

Gleason Crown Wheel 8 Sets(608/609, 606/607, No.11 & No. 22)

Gleason Pinion 7 Sets(No.116 & No.16)

Oerlikon 9 Nos. (SM3, S17, SKM1)

CUTTING EQUIPMENT INSTALLED

Transmission Gears Hobbing 26 nos

Shaping 26 nos

Shaving 14 nos

Straight Bevel Gears Gleason Coniflex114 02 nos

Gleason Coniflex104 02 nos

Coniflex WMW 26 nos

CUTTING EQUIPMENT INSTALLED

HEAT TREATMENT FACILITIES

Sealed Quench Furnaces

Continuous Gas Carburising Furnace

Gas Carburising Furnaces

Rotary Hearth Furnaces

Pusher Type Furnace

Quench Presses – Oerlikon, Klingelnberg, & Gleason

Tempering Furnaces

Manganese Phosphating Facilities

Shot Blasting Equipments

Straightening Presses

•Cylindrical Grinding Machines -10 Nos.

•Internal Grinding Machines - 5 Nos.

•Spline Grinding Machine - 1 No.

•Lapping Machines•Gleason - 11 Nos.(503/506/119/513/516)

•Oerlikon (SKL-1) - 1 No.

•Gear Testers-Gleason - 13 Nos.(502/511/17-A)

FINISHING EQUIPMENTS

Full range of Hardness Testers

(Rockwell, Brinell, Vickers, Micro Vickers)

Hardenability (Jominy) Apparatus

Microscope with camera and image analyzer

Crack detection Equipment [Magnaflux]

Macro Etching

Manganese Phosphating Solution Analysis

Muffle Furnaces

Sample Cutting / Polishing Machines

METALLURGICAL LAB FACILITIES

Includes:

• CMM with Gear Analyser

• Lead and profile testers

• Surface Roughness tester

• Contouro Graph

• Profile Projectors

• Digital Temperature Calibrator

•Wear Check Plug for Thread Ring Gauge Calibration

METROLOGY LAB FACILITIES

RAW MATERIAL

 Forgings are received Heat Code wise duly

Isothermally Annealed/ Normalised.

Checks before processing are:

•     Visual Inspection for cracks and folds.

•   Check of chemical composition by Spectro Analysis.

•     Hardness.

•     Jominy Hardenability.

•     Micro structure and Inclusions.

•    Grain Size and Grain flow.

QUALITY SYSTEMS

IN-PROCESS

       First off inspection &

  Patrol inspection at defined interval as per control plan

For Bevel Gears check tooth contacts in soft Gears

Before Heat Treatment inspection for all parts ensuring removal of any sharp edges and burrs.

For Bevel Gears Final Testing to ensure backlash at correct mounting distance, tooth contact, run out and marking mounting distance variations.

QUALITY SYSTEMS…….Contd.

HEAT TREATMENT

Batches are subjected to checks on:

Effective Case Depth

Core and Surface Hardness

Microstructure- Case & Core

Flatness & ovality of bore for Crown Wheels

Straightness for Shaft items

Magnetic particle inspection by Magnaflux

QUALITY SYSTEMS…….Contd.

•Additional Continuous Gas Carburising Furnace

•Sealed Quench Furnaces

•CNC Hobbers

•CNC Shapers

•CNC Shavers

•CNC Internal Grinder

•CNC External Grinders

•CNC Gleason/Oerlikon, Dry/Wet Cutting System for Crown Wheel & Pinion (under consideration)

INVESTMENT COMMITTED

CUSTOMER PROFILE – DOMESTIC OEMsAUTOMOTIVE

•TATA MOTORS

•MAHINDRA & MAHINDRA

•DANA INDIA

•SCOOTERS INDIA

•AMERICAN AXLE &MANUFACTURING

CUSTOMER PROFILE – DOMESTIC OEMsAGRICULTURE

•TRACTOR & FARM EQUIPMENT

•INTERNATIONAL TRACTORS

•JOHN DEERE EQUIPMENT

•NEW HOLLAND TRACTORS

•INDO FARM EQUIPMENT

•STANDARD COMBINES

CUSTOMER PROFILE – DOMESTIC OEMs

CONSTRUCTION EQUIPMENTS & OTHERS

•JCB INDIA

•TELCO CONSTRUCTION EQUIPMENT

•ACTION CONSTRUCTION EQUIPMENT

•EICHER MOTORS

CUSTOMER PROFILE – EXPORT OEMs

•UZEL MAKINA SANAYI A.S., TURKEY

•MEGA MOTORS COMPANY, IRAN

•IRAN TRACTOR MFG COMPANY, IRAN

•ARVIN MERITOR, BRAZIL

We also Export our products to Importers, Gear Makers & After Markets in:

USA , U.K., France, S. Africa, Indonesia, Malaysia, Thailand, Singapore, Burma, Syria, Egypt, Turkey, Bangladesh, Sri Lanka, Iran, Dubai, Italy, Argentina, Australia, Hungary, Germany, Brazil etc.

CUSTOMER PROFILE - EXPORTS

FORGING FACILITIES AT LUDHIANA

• Friction Belt Drop Hammer (1.00, 1.50, 2.00, 2.50, 3.00, 6.00, 8.00 M.T.)

• Up Setter - 3 Inches & 6 Inches

• Furnaces for Isothermal annealing & normalizing

• Fully equipped die making facilities

• Material testing facilities includes Spectro Meter & Universal Testing Machine along with Izol Impact & Charpy Testing Machines

• 100% back up with Captive Power

• An ISO 9001: 2008 certified

FACILITIES AT SITARGANJ

• Green Field Plant having shed & flooring ready

• Continuous gas carburising & sealed quench furnaces under commissioning at site

• Cutting equipments identified & under movement to site

• Key personnel identified

• Production expected to start in December 2009

• Production & capacity planned

• Crown Wheel & Pinion- 120,000 Sets• Straight Bevel Gears - 300,000 Nos.• Transmission Gears - 400,000 Nos.

PUNJAB BEVEL GEARS LIMITEDB-44/1 & 52/2, Site-IV, Industrial Area,Sahibabad-201010, Ghaziabad (U.P) IndiaTel.: +91-120-2895386/2895320/2896075/2895344Fax: +91-120-2896099/2896059Email: mktg@pbgl.inWeb Site: www.punjabbevelgears.com

PLANT ADDRESS