REPORT ON INDUSTRIAL

TRAINING
IN
JTEKT INDIA LIMITED

SUBMITTED TO: Dr. Rachna Yadav

SUBMITTED BY: Abhijeet Kumar (2K17/ME/007)
Abhishek Memroth (2K17/ME/013)
Ajay Kumar (2K17/ME/021)
 ACKNOWLEDGEMENT
We (Abhijeet Kumar, Abhishek Memroth & Ajay Kumar)
students of Delhi Technological University would like to
pay our heartfelt thanks to the JTEKT INDIA LTD. for
providing an immense knowledge and cooperation. We
would like to express our gratitude to Dr. RachnaYadav.
We are grateful to our training guide, inspiration and
constructive suggestion that is helpful for us during the
training period.
1. Mr Alok Verma
2. Mr Sashi Kumar
 INDEX

S.NO. TITLE

1 INTRODUCTION TO STEERING SYSTEM

2
RACK AND PINION STEERING

3
INTRODUCTION TO JTEKT INDIA LIMITED

4
PRODUCTION DEPARTMENT

5
PRODUCTION OF PINION
INTRODUCTION TO STEERING SYSTEM

THE STEERING SYSTEM

 The steering system consists of the components that allow
the driver to turn the front wheels of the vehicle, and for a
few vehicles, provides for a limited amount of steering by
the rear wheels.

FUNCTIONS OF THE STEERING SYSTEM

 The most basic function of the steering system is to allow
the driver to safely and precisely steer the vehicle.
 The steering system also provides a way to reduce driver
effort by making the act of steering the vehicle easier.
MANUAL STEERING SYSTEMS

 Cars and trucks built before the 1950s had manual steering
systems, meaning that the effort needed to turn the
steering wheel.
 Turning the wheels still required a lot of muscle power,
and drivers could become quickly fatigued when
conditions required them to turn the wheels often.

HYDRAULICALLY ASSISTED POWER STEERING

SYSTEMS

 Chrysler offered the first power steering equipped vehicle

in 1951.
 Hydraulic power-assisted steering uses a belt-driven
hydraulic pump, called the power steering pump, to supply
pressurized fluid to the steering gear.
 The pressurized fluid then applies force to a piston inside
the steering gear.
 With the addition of the force applied by the fluid, the
effort required by the driver to turn the wheels is reduced.
 The power steering pumpconsumes a small amount of
engine power to operate, which results in a slight loss in
engine power and economy.
ELECTRICALLY ASSISTED POWER STEERING SYSTEMS

 A recent change in power steering is the replacement of the

belt driven hydraulic pump by electric motor assist.
 There are currently three types of electric assist available:
o Electrically powered hydraulic steering
o Columns drive electric steering
o Electric motor-assisted rack and pinion steering gear
 The completely electric types do not use any type of fluid,
and so they are more environmentally friendly since no
fluid loss can occur.

STEERING RATIO
 The number of complete turns of the steering wheel
compared to the total amount of wheel and tire movement
is called the steering ratio
JTEKT INDIA LIMITED (GURGAON)
JTEKT India Limited:

 JTEKT India Limited (formerly known as Sona Koyo Steering

Systems) is a part of JTEKT Corporation Japan and operates as part
of JTEKT Group India.

 It is engaged in the business of manufacturing / production,

supply and sale of steering systems, viz. steering gears, columns
and RPS assemblies, axle assemblies and other auto ancillaries to
almost all Indian passenger car and utility vehicle manufacturers.

 Earlier in 2017, JTEKT Corporation successfully completed the

strategic acquisition of its partner Sona Koyo Steering Systems
Limited to cement its positioning in the Indian auto components
market.

 It is committed to growing India as a critical centre of its

operations in South Asia. As a global brand, JTEKT will be bringing
into India its proprietary technologies to further address the
evolving needs and customer dynamics. The company will
continue to grow its focus on India becoming a key manufacturing
and distribution hub.
PRODUCTION DEPARTMENT

RACK AND PINION STEERING (RPS)

 The traditional recirculating ball gearbox, which is a heavy
piece of cast iron and steel, has been replaced in most
vehicles with a rack and pinion gearbox.
 A rack and pinion assembly has two main components, the
rack gear and the pinion gear, enclosed in housing.
 In a rack and pinion, the steering shaft is connected to the
top of the pinion gear, which is held in the rack by a set of
pinion bearings.
 The bottom of the pinion shaft has the pinion gear, which is
meshed with the rack gear.
 The rack gear is a gear that has been flattened out with the
teeth in a straight line.
 When the pinion gear turns, it moves the rack gear side-to-
side.
 The rotary motion from the steering wheel is turned into a
linear motion to move the wheels.
 Benefits of the rack and pinion
1. The reduced weight of the component.
2. The rack gear attaches to inner tie rods, which in
turn connect to outer tie rods.
3. The rack and pinion assembly eliminates the
Pitman arm, idler arm, and center link found on
parallelogram linkage systems.
PINION PRODUCTION

o For the production of pinion we need a basic material i.e. raw

material from which pinion is made.
o Here we use SCM430 material which is an alloy of chromium &
molybdenum which increases the strength and resistance from
oxidation.
TURNING PROCESS
o There are four process for turning of pinion
i. FACING & CENTRING
 It is a turning machine.
 It can chamfer & bore the raw material from
both ends.
 Depth of bore is dependent on the product
requirement.
 For ALTO pinion the depth of bore can be 2.070
with error of 0.005.
 Dimensions are checked using various gauges.
 If dimension are ok then it is transferred for next
process
 ii. TURNING
 PRINCIPAL:-
 It is a material removal process which is used to
create rotational parts by cutting away
unwanted material.
 It requires turning machine or lathe.

iii. HEAT CODE PUNCHING & SERRATION ROLLING

 PRINCIPAL OF ROLLING:-
 Heat code punching is done for the identification
of product by giving some characteristic number
or alphabet.
 Now product undergoes serration rolling where
formation serration takes place.

iv. SOFT GRINDING

 PRINCIPAL:-
 It is also a machining process processes that uses
a grinding wheel or grinder as the cutting tool.
 It is used for high quality surface finish with high
accuracy of shape &dimension.
o Now turning of material is completed & it is transferred
for Hobbing process.
HOBBING PROCESS
 PRINCIPAL:-
 It is a machining process for gear cutting, splines

cutting.
 In this process formation of teeth takes place.

o After Hobbing process pinion is transferred to the heat

treatment process.

HEAT TREATMENT PROCESS

 This treatment results in an improvement of the

mechanical properties (Elasticity, Ductility, toughness ,UTS
etc.) as well as an increase in the level of hardness,
producing a tougher, more durable item.
 It removes residual stresses (Residual stresses are locked-
in stresses within a metal object, even though the object is
free of external forces. Residual stresses can be tensile or
compressive.)

1. BATCH CODE PUNCHING

 Batch of pinion is formed
 This batch is coded with characteristic letter,
number etc.
2. PREPARATION OF LOT
3. WASHING OF PINIONS
 To Remove excess oil
4. PREHEATING
 Heating of material around 400°C.
5. CASE HARDENING
 CARBURIZING:-
o It is also referred as Case Hardening
o It makes the surface harder which is resistant
to wear, while maintaining toughness and
strength of the core.

o Carburizing diffuses carbon into the surface of

the steel creating a case while retaining a
substantially lesser hardness in the
core(because if core is made hardened then it
would not absorb the shock and vibration and
thus lead to failure.)
o This treatment is applied to low carbon steels
after machining.

PROCESS
o Carburizing is done by heating components in
sealed atmosphere furnace, and introducing
carburizing gases at temperature.
o Gas carburizing allows for accurate control of
both the process temperature and carburizing
atmosphere (carbon potential).
 o Carburizing is a time/temperature process;
the carburizing atmosphere is introduced into
the furnace for the required time to ensure
the correct depth of case.

6. TEMPERING
 It is done for following reasons
o To reduce hardened steel & thus to increase
ductility.
o To remove internal stresses.
o To steel tough to resist shock & fatigue.

 Tempering process consists of reheating the

hardened steel to some temperature below the
lower critical temperature, followed by any desired
rate of cooling.

7. METALLURGICAL INSPECTION
8. SHOT BLASTING
 It is a surface treatment process using high velocity
casted steel.
 Through this process excellent cleaned surface can
be obtained.

9. STRAIGHTENING
 This process is used to make product straight.
 10. THREAD ANNEALING
 This process is done for thread part only, therefore
known as thread annealing.
 This process is required for following reason
o To soften the steel so that it can be machined
& cold work easily.
o To relieve internal stresses.
 ANNEALING PROCESS
o Heating the steel 30°C - 40°C above the upper
critical temperature for hypo-eutectoid steel
and with same temperature above lower
critical temperature.
o Holding at this temperature for some time to
enable internal changes to takes place.
o Cooling slowly in furnace.
Now the processes of heat treatment are completed & product
is transferred for PINION HARD GRINDING.

PINION HARD GRINDING

 After heat treatment pinion become hard but losses its
surface finishes.
 Now it undergoes grinding process forhigh quality surface
finish with high accuracy of shape & dimension.
MPI (MAGNETIC PARTICLE INSPECTION)
 This is also a surface NDT method & based upon
magnetism
 In MPI we take the help of magnetism to inspect
defect and flaws.
 PRINCIPLE:- It can be considered as a combination of
two nondestructive testing methods:
o MAGNETIC FLUX LEAKAGE TESTING
 When a bar magnet is broken, two
complete bar magnets (with magnetic poles
on each end of each piece) will form.
 If the magnet is just cracked but not broken
completely in two, a north and south pole
will form at each
edge of the
crack. The magnetic
field spreads out
when it encounters
the small air gap created by the crack.
When the field spreads out, it appears to
leak out of the material and, thus is called a
flux leakage field.
 o VISUAL TESTING
 If iron particles are sprinkled on a cracked
magnet, the particles will be attracted to and
cluster not only at the poles,but also at the
poles of the edges of the crack. This cluster
of particles is much easier to see than the
actual crack and this is the basis for
magnetic particle inspection.

 PROCESS OF INSPECTION
1. Magnetize the component that is to be inspected.
If any defects on or near the surface are present,
the defects will create a leakage field.
2. After the component has been magnetized, iron
particles, either in a dry or wet suspended form,
are applied to the surface of the magnetized part.
3. The particles will be attracted and cluster at the
flux leakage fields, thus forming a visible indication
that the inspector can detect.
DEMAGNETISATION OF THE COMPONENT

Now the pinion is ready for assembly process.