The present disclosure relates to an axle (200). The axle includes a beam (202), a LH spindle (204), and a RH spindle (206). The beam (202) has a first end (208) and a second end (210). In addition, the LH spindle (204) is integrally formed at the first end (208). Further, the RH spindle (206) is integrally formed at the second end (210). Furthermore, the axle (200) is manufactured using a closed die hot forging process.
The present disclosure relates to an axle (100) and a method (500) of manufacturing the axle (100). The axle (100) includes spindles (102), pads (104) and central areas (106). Further, the axle includes a first bias (401) and a second bias (402). The first bias (401) is symmetrically downwards at pads (104) of the axle (100) and the second bias (402) is symmetrically sidewards at spindles (102) of the axle (100). The method (500) for manufacturing an axle (100) of a vehicle includes steps of, heating (501), a billet in a furnace (202). Further, reduce rolling (502) the billet to form a Reduced Rolled (RR) preform (300). Furthermore, bending (503) the RR preform (300), to form a bender preform (400). Also, the bender preform (400) is bent in more than one planes in a multi-plane bender assembly (201).
The present invention relates to an apparatus to determine degradation in properties of material used to manufacture a component which is subjected to thermal and chemical loads during its working. It comprises: gas chamber (114); a first inlet (104) for transmitting steam; a second inlet (106) for transmitting calibration gas; both inlets connected to a mixer (110) in which the calibration gas and steam are mixed to form a mixture; said gas chamber (114) to receive the mixture via a connecting pipe (128), the connecting pipe has a first valve (118) to control flow of the mixture; a second valve (108) for purging nitrogen gas; a flame arrestor (112); a specimen holder (120) to hold specimen (122); a window (116) in line with the specimen holder (120); a laser source (102) to emit a laser pulse through the window (116) to generates thermal shocks on the specimen (122).
A system, for synchronizing movement between a driver component (12) and a driven component (20), comprising: an 'A' frame (14) coupled to a tow hook (11), said A-frame (14), coupled to a driven component (20), having multiple degrees of freedom with respect to said tow hook (11); a guide / U-clamp (16) mounted on an angle measuring rod (18), said guide / U-clamp (16) and said angle measuring rod (18) interfacing with said 'A' frame (14); and a gear box (25) on which an encoder (20) is mounted, said gear box (25) coupled with said angle measuring rod (18), said encoder (20) configured to provide an electrical output corresponding with sensed angular displacement, said encoder (20) providing steering angle (ST) as a function of movement of angle measuring rod (18); in order to ensure steering, correlative to said steering angle (ST), in a defined range, thereby avoiding oversteering or understeering.
A system for synchronizing speed-dependent and turning-radius-dependent movement between a driver component (12) and a driven component (20), comprising: a first speed sensor to sense speed of an operative inner wheel of a driven component (20); a second speed sensor to sense speed of an operative outer wheel of a driven component (20); a processor to determine steering angle (ST) for controlling angle of each of said driven steerable rear wheels in response to sensed speed and angle of turn of front operative inner and outer wheels, said processor configured to compute difference in speed between said front operative outer wheel and said front operative inner wheel to provide a processed output, comprising a first angle (δi) for said steerable rear operative inner wheel and a second angle (δo) for said steerable rear operative outer wheel; in order to ensure steering in a defined range, thereby avoiding oversteering or understeering.
A system for controlling movement of driven component (20) based on movement of driver component (12), said system comprising: an 'A' frame (16), coupled to a tow hook (14), configured to be coupled to a driven component (20), said 'A' frame (16) having multiple degrees of freedom with respect to said tow hook (14); draw wire sensors (22a, 22b) used to measure length between said driver component (12) and an associated said driven component (20), in that, a first draw wire (22a) being coupled to a first potentiometer (30a), and a second draw wire (22b) being coupled to a second potentiometer (30b), said first potentiometer (30a) being configured to sense distance between said driver component (12) and said driven component (20), said second potentiometer (30b) being configured to sense distance between said driver component (12).
The invention discloses a process of manufacturing of the crown gear. The teeth profile and face of crown gear is manufactured in the assembled condition with differential housing/casing. The process comprises the steps of turning, PCD hole drilling on the turned disc, gear bobbing on the drilled disc, chamfering of the hobbed disc, heat treating and hard turning of the chamfered disc to produce a crown gear and cleaning it, followed by assembling the crown gear with the differential housing and carrying out bottom face grinding and teeth grinding in the assembled condition with help of specially designed apparatus wherein the apparatus comprises Fixture- 1 and Fixture-2 which facilitate hydraulic actuations of the necessary components and also concentricity and perpendicularity/squareness of the necessary components during the grinding process.
B23P 15/14 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
B23F 19/00 - Finishing gear teeth by other tools than those used for manufacturing gear teeth
8.
STEEL FOR HIGH TEMPERATURE CARBURIZING AND ITS METHOD OF PREPARATION
The present invention provides a steel composition for high temperature carburizing and a steel article made from the steel composition. The composition comprises: a) 0.11 to 0.3 wt.% of Carbon, b) 1.1 to 1.4 wt. % of Manganese, c) 0.15 to 0.35wt. % of Silicon, d) 1 to 1.3 wt. % of Chromium, e) ≤0.0006 wt. % of Boron, f) 0.04 to 0.05 wt. % of Titanium, g) 0.035 to 0.056 wt. % of Niobium, h) <0.2 wt. % of Nickel, i) <0.06 wt. % of Molybdenum, j) <0.025 wt.% of Sulphur, k) <0.025 wt.% of Phosphorous, l) 0.02 to 0.03 wt. % of Aluminium, m) ≤190 ppm of Nitrogen, and n) the rest is Iron (Fe).
C22C 38/44 - Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
C22C 38/48 - Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
C22C 38/04 - Ferrous alloys, e.g. steel alloys containing manganese
C23C 8/00 - Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
9.
NOZZLE GUIDE VANE AND MANUFACTURING METHOD FOR THE SAME
This invention provides an integral nozzle guide vane (NGV) and an additive method of manufacturing of said integral nozzle guide vane (NGV) in jet engine turbine section. In the present manufacturing method, the integral nozzle guide vane is made by using digital model and layer by layer material build-up approach. This tool-less manufacturing method can produce integral nozzle guide vanes, along with cage and cage ring, in a short time with high precision.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
The present invention provides an integral fuel supply micro tube comprising a micro tube and a hollow screw manufactured by an additive manufacturing process. The integral fuel supply micro tube is manufactured using a single building block in a single printing cycle, using an optimised support for holding the integral fuel supply micro tube being printed and dissipating heat to surrounding, thereby eliminating excessive inventory which results in cost saving.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
The present invention provides an additive manufacturing process for manufacturing turbine impeller. The presently provided process is a tool-less manufacturing method which produce a uniform turbine impeller in a short time with high precision.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
The present invention relates to an apparatus and heat treatment process for a front axle beam to provide distortion free heat treatment of a front axle beam. The apparatus for carrying out distortion free heat treatment of a front axle beam comprises a receptacle for placing the front axle beam to be quenched; actuators for centering said beam axially and transversely inside said receptacle; clamping mechanisms for vertical and horizontal clamping of said beam inside said receptacle; and actuators for constraining the distortion of KPB in vertical or transverse direction. The apparatus envisaged in the invention is designed such that it supports and/or holds the FAB at its most critical locations during the heat treatment process. Due to this, the FAB remains distortion-free and hence, does not require any bend/distortion correction and stress relieving after the heat treatment process. The heat treatment process of the invention incorporates the step of using the apparatus of the invention to carry out the quenching process.
The present invention relates to a 3D printed combustion chamber assembly and an additive manufacturing of the combustion chamber assembly. The process involves spreading metal powder layer by layer on a predetermined platform followed by fusion, heat treatment, wire cutting operation, shot blasting and buffing operation to obtain a combustion chamber and flame tube parts with pre-detrmined surface finish; and press fitting the combustion chamber and flame tube parts to obtain the combustion chamber assembly.
The present invention discloses a Fluid End and its manufacturing method. The conventional fluid end manufacturing methods involve machining of all surfaces. This demands more input stock for manufacturing process and a lot of material wastage during machining process. In the conventional processes involving open die forging followed by machining result into only about 34% utilization of material. In the present invention, fluid end component geometry is optimized. Assembly surfaces are machined whereas other or non-assembly surfaces are as-forged condition. The method of invention also results in significant reduction in machining time and chip removal. The present invention also discloses a process of manufacturing using a combination of open die and closed die forging, and machining. It involves the steps of cogging an ingot to form billet for closed die forging using open die forging, forging the billet in closed die using forging equipment, semi-finish/rough/partial machining, heat treatment, drilling and finish machining the component. Most of the non-assembly areas of the fluid end are left in as-forged condition.
B21K 1/26 - Making machine elements housings or supporting parts, e.g. axle housings, engine mountings
B23P 15/50 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools threading tools dies
C21D 9/00 - Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
F04B 53/00 - Component parts, details or accessories not provided for in, or of interest apart from, groups or
F16L 41/02 - Branch units, e.g. made in one piece, welded, riveted
F04B 1/053 - Multi-cylinder machines or pumps characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with actuating or actuated elements at the inner ends of the cylinders
F04B 27/053 - Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders having cylinders in star- or fan-arrangement with an actuating element at the inner ends of the cylinders
The present invention is directed to an integral planet carrier with no joints, a method of manufacturing it and an apparatus for doing so. Such integrally manufactured components have better strength than a conventionally produced multi-piece jointed planet carriers or integral planet carriers made from casting process. The present invention provides a hot forging process which can be used for the manufacturing of the planet carrier. The manufacturing process comprises of forward extrusion of a billet followed by backward extrusion. This is followed by bending operation, which is in turn followed by a flattening operation. Post- forging heat treatment and other treatments such as shot blasting follow. Finally machining is carried out to arrive at the final integrally formed planet carrier. The forward extrusion, backward extrusion, bending and flattening operations are done on a press or hammer having sufficient energy and load capacity. Preferably these operations are performed on a hydraulic press in order to achieve the required accuracy and precision.
F16H 57/08 - General details of gearing of gearings with members having orbital motion
B21J 5/02 - Die forging; Trimming by making use of special dies
B21D 11/02 - Bending by stretching or pulling over a die
B21J 1/06 - Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
B21C 1/10 - Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums with two or more dies operating in series in which the material does not slip on the drums with accumulation of material between consecutively-arranged dies
The present invention relates to a newly designed preform (14) of predetermined shape and size. A shape of said perform (14) is chosen to reduce the number of operations to be performed during the forging process. Further, there are provided dies which are adapted to perform twisting and flattening simultaneously, said die comprises plunging locators. Said plunging locators are adapted for robust and consistent location of extruded pre-form on buster dies. According to another aspect, the present invention also relates to a forging apparatus (10) for performing forging operation. The apparatus (10) is designed to accommodate the preform (14) of predetermined size. The apparatus (10) may include a top die (22) and a bottom die (24) where each die includes at least one locator or plunger (26, 28) that facilitates in placing the predetermined shaped preform in the apparatus (10).
Invention relates to a method of producing a crown wheel with near-net shaped as-forged teeth having continuous grain flow lines and having minimal machining allowance. The method of invention comprises the steps of making ring using hammer forging and ring rolling technique followed by blocker and finisher forging step for manufacturing of gear teeth on the ring and after which a cold coining operation is performed on the finished forging to achieve near net shape of gear teeth. The cold-coining operation allows a reduced machining allowance of up to 0.3mm but with minimal dimensional variation of teeth. These near net shaped teeth's are further finished to final shape by grinding operation. The forging of near net shape gear teeth profile is carried out using any type of press capable of applying required force. Representative Figure: Figure 3
B21H 5/02 - Making gear wheels with cylindrical outline
B21J 5/02 - Die forging; Trimming by making use of special dies
B23P 15/14 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass gear parts, e.g. gear wheels
B21J 1/06 - Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
C21D 9/32 - Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for gear wheels, worm wheels, or the like
18.
RIGID LIGHTWEIGHT FRONT AXLE BEAM AND MANUFACTURINGTHEREOF
The present invention relates to a light weight axle beam (100) having strengthening rib arrangement (16) at a region of the axle beam where stress due to torsional forces or fatigue loading attains maximum value during the operation of the axle beam. The arrangement of at least one stiffening rib provides stiffness to beam to withstand torsional and bending loads; and improved deflection characteristics.
In accordance with the present invention there is provided a method of manufacturing an integral axle shaft; said method comprises forging a flange and a shaft with spline end separately and electron beam welding of said flange and said shaft with spline end to obtain an integral axle shaft. The present invention also provides an integrated axle shaft (100) comprising a flange (12) and a shaft (14) with spline end (20), said flange (12) comprises a pilot stub (16) or a pilot hole of pre-determined size and shape at the centre of said flange, whereas said shaft (14) comprises a pilot hole (18) or a pilot stub of pre-determined size and shape at the centre of one ends of said shaft and a spline end (20), wherein said flange and said shaft being forged separately and joined together by circumferential electron beam welding.
: The present invention provides a method of manufacturing a steering knuckle; said method comprising forging a tie rod arm, a stem, and a base knuckle separately; and electron beam welding said tie rod arm 5 and said stem to said base knuckle to form the steering knuckle. The present invention also provides a steering knuckle (100) comprising a base knuckle (12) having pilot stub or pilot hole; a tie rod arm (14); and a stem (16), wherein said tie rod arm (14) comprises pilot stub or pilot hole, said tie rod arm being electron beam welded to said base 10 knuckle (12); and said stem (16) comprises pilot stub or pilot hole, said stem being electron beam welded to said base knuckle (12). 2
Conventionally, pinion drives are manufactured using multistep processes such as casting or forging, followed by various machining processes, and have shortcomings such as significant wastage of material and resources, requirement of precision tooling, cutting of the grain flow lines resulting in the grain flow lines that are neither continuous nor follow the profile of the teeth, resulting in pinion drives of lower strength and life, and cumbersome ejection mechanisms. The invention discloses a method of producing as-forged near net shape pinion drive having as forged gear teeth with continuous grain flow lines conforming to the profile of the teeth, using sequential forging operation, and a finisher die assembly that ensures automatic and easy ejection of forged part. The process of invention involves deployment of a finisher die assembly which is designed to provide a gap between the top surface of the top finisher die and corresponding inside surface of the top finisher die holder of the assembly.
The invention discloses a method of producing a Crown Wheel involving production of a ring by ring rolling process and further production of near net shape tooth profile by sequential stepwise forging. Conventional methods have several disadvantages e.g. excessive machining time, expensive gear cutting equipment, short life of cutting tools, possible strain hardening and residual stresses in the cold-forged parts and subsequent distortion during heat treatment and a high level of rejection of parts, among others. The invention discloses a method of manufacturing near-net shape crown wheel comprising the steps of making an annular ring using hammer forging, punching, piercing and ring rolling followed by blocker and finisher forging for manufacturing of gear teeth on the ring. Blocker forging is followed by trimming and piercing operation for flash removal. Hot forging operation (hammer blocker forging and finisher forging) is followed by cold coining process for improving the precision of the as-forged teeth profile.
The invention discloses a process of manufacturing heavy and critical components such as a blowout preventer (BOP) with a combination of open die forging, piercing and machining process which results in to better material utilization and saving in the machining time. The forging process of the invention involves a step of notching, wherein a transverse notch is made near each end of the ingot before cogging said ingot. The invention allows development of safety and critical components with effective material utilisation.
The present invention discloses a Fluid End and its manufacturing method. The conventional fluid end manufacturing methods involve machining of all surfaces. This demands more input stock for manufacturing process and a lot of material wastage during machining process. In the conventional processes involving open die forging followed by machining result into only about 34 % utilization of material. In the present invention, fluid end component geometry is optimized. Assembly surfaces are machined whereas other or non-assembly surfaces are as- forged condition. The method of invention also results in significant reduction in machining time and chip removal. The present invention also discloses a process of manufacturing using a combination of open die and closed die forging, and machining. It involves the steps of cogging an ingot to form billet for closed die forging using open die forging, forging the billet in closed die using forging equipment, semi-finish/rough/partial machining, heat treatment, drilling and finish machining the component. Most of the non-assembly areas of the fluid end are left in as-forged condition.
The weight of the crankshaft is among the many factors that adversely influence the engine performance. Reducing the weight of the crankshaft without affecting its strength and balancing characteristics would improve the engine performance. The present invention provides a crankshaft and the process of manufacturing it such that its weight is reduced at least by 5-10% in contrast to conventionally manufactured crankshafts of comparable specification. This is achieved by reducing machining allowance which is provided during forging design, such that it does not adversely impact its strength and balancing ability. Moreover the additional aspect of kidney pocket inclusion into the combined area of web and counterweight profile reduces weight of crankshaft further at least 5%. A reduction in total machined area of the webs is also another aspect of the present invention.
A process to manufacture crusher hammers by forging used in coal granulator of thermal power plant is disclosed. It uses step-wise forging operation to achieve final shape of crusher hammers, followed by unique heat treatment. The process starts with a preform made from a round billet and follows through with a upsetting followed by finisher forging, flash trimming and piercing operation. The forged components are further heat treated to get improved mechanical properties (strength, wear resistant, hardness, toughness etc.) and longer life. The hammers made using conventional processes have low life due to high wear rate and it may increase cost of replacement in very early stage. This problem is solved by the hammers manufactured by the process of invention.
The present invention disclosed an ultra-high strength steel for structural components, a process of making such steel that has a desirable microstructure in the thermo-mechanically processed and differently cooled conditions that delivers high fatigue performance in service, and a process of making forged components using such steel. The steel and the process of its manufacturing enables manufacture of components that exhibit bainitic microstructure that impart ultra- high strength ranges with very high fatigue performance. The invention enables saving in alloying additives compared to hardened and tempered alloy steels and in addition avoid expensive heat treatment operations to achieve the desired range of mechanical properties. The steel of the invention is a suitable replacement for micro alloyed steel or heat treated steel bars used for structural component development. The steel can be used for applied as the hot rolled and air cooled long products that can be directly used for applications or it can be directly hot forged in open or closed die forging followed by controlled cooling to achieve the desired microstructure and range of mechanical properties.
The present invention discloses a modified process of die manufacturing which substantially improves the wear life of the dies. The process consists of introduction of shot blasting operation after the machining operation and before the nitrocarburising operation. The process increases the case depth of the surface hardened layer thereby increasing the wear life of the hot forging dies. Gaseous Ferritic Nitrocarburising (GFN) process is carried out on die steel material for increasing the surface hardness. Performance of the surface hardening process depends on surface preparation and its treatment. Surface preparation entails modifying roughness and residual stresses on the surface. The shot blasting step of the invented process introduces uniform roughness and compressive residual stresses on the surface, which helps to increase the hardening depth during GFN.
The present invention eliminates the rolling and/or cogging process from the complete crankshaft manufacturing cycle, by using continuously cast (ConCast) billets of the size required by the forging process, thus, eliminating the requirement of cross section reduction through rolling and/or cogging. Moreover, proper forging process design is done to take care of closure of internal porosities and centre looseness, breaking of as cast structure and required grain flow during the forging operation. Thus, the crankshaft produced by the invented process has properties - mechanical, metallurgical, fatigue- equivalent to those produced by the conventional process.
A forging process to manufacture Aluminium wheel discs for heavy vehicles using small tonnage hammer is disclosed. It uses step-wise forging operation to achieve final shape of the alloy wheel. A minimal amount of machining is required. The process starts with a preform made from a round extruded billet and follows through with a pancaking and buster operations further followed by blocker and finisher operations. It is noted that grain flow lines in the product are continuous because the initial flow lines are present in extruded billet and it has greater material strength than the products manufactured with conventional processes that involve joints and welding.
The present invention discloses high frequency vibration assisted turning apparatus and method for Ti alloy work pieces. The invention is also applicable to alloys that are hard to machine in general. It is a novel manufacturing technology, where high frequency vibrations are imposed on the conventional movement of the cutting tool. As an example frequency of 20 kHz and amplitude of 20 μm are provided to the cutting tool in the direction of feed given to tool holder. The method results in reduction of shear friction at the contact between the tool and the work piece, which in turn results in the reduction in shear band formation in this high frequency assisted turned chips. There are benefits which results in terms of improved chip mechanism and tool life. It is observed that the High Frequency Turning produces a better surface finish that the conventional methods.
B23B 1/00 - Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
B23P 25/00 - Auxiliary treatment of workpieces, before or during machining operations, to facilitate the action of the tool or the attainment of a desired final condition of the work, e.g. relief of internal stress
32.
A FORGING DIE ASSEMBLY WITH SPLIT CASSETTES AND A METHOD TO MAKE IT
The present invention is a forging die assembly comprising at least two die inserts and at least a lower cassette and an upper cassette, which are placed between a top die holder and a bottom die holder, such that the lower or upper cassette or both are of the split type and the split cassette is held together with a set of tie rods. The invention thus proposes a method of making a forging die assembly using split cassettes. The assembly made using the invention is capable of withstanding the alternate stresses developed during a closed die forging process. The invention also provides a method for reusing cassettes damaged during closed die forging.
The invention discloses a process of manufacturing heavy and critical components such as a blowout preventer (BOP) with a combination of open die forging, piercing and machining process which results in to better material utilization and saving in the machining time. The forging process of the invention involves a step of notching, wherein a transverse notch is made near each end of the ingot before cogging said ingot. The invention allows development of safety and critical components with effective material utilisation.
The present invention describes a method of manufacturing a near-net shaped hollow shaft useful for high power applications such as gearboxes for wind energy industry. The method involves providing a concast bloom (of a round or rectangular or of any polygonal cross section) or an as-cast round ingot from which a hollow perform is prepared using hollow die punching, followed by process of heat treatment, proof-machining and stress relieving.
B21C 1/00 - Manufacture of metal sheets, wire, rods, tubes or like semi-manufactured products by drawing
C21D 8/10 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of tubular bodies
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
C22F 1/18 - High-melting or refractory metals or alloys based thereon
F03D 11/02 - Transmission of power, e.g. using hollow exhausting blades
35.
A METHOD TO REDUCE END DEFECTS IN ROLLING OF SECTIONS
The present invention aims at reducing the cropping losses formed during reversible multi pass hot rolling of flat ended bloom into bars by designing the preform end shapes using finite element analysis and a method to provide the designed preform end shapes to the input blooms. A three dimensional simulation of the reversible multi pass hot rolling process with flat ended input bloom predicts the formation of defective end shapes after rolling and reverse material tracking is applied to finite element simulations to obtain desired preform end shapes of the input bloom and similar simulations on the bloom with preformed end shape shows considerable reduction in cropping losses.
B21B 15/00 - Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
patents
