ZERO DEFECT PLANNING OF CASE HARDENED

TRANSMISSION GEARS -A CASE STUDY

*Prof. P. Thareja
**Manu Goyal,
Abstract

Defect abatement is the most vital activity for any metallurgical engineer (Thareja, 2006), . It is so
because an unscheduled incidence of defects causes delays, disposal of defected inventoriess and
dumping of plans and schedules of deliveries. A defect is virtually a denial of promise, which puts
plans haywire (Thareja, 2008).

The planning of defects free production is therefore very important (Thareja and Goyal 2005). This
work is intended to implement the rigour in case of transmission gears for Tractors. The gears
undergo distortion during case hardening and heat treatment. The work reports improvement in the
Composite error achieved significantly after heat treatment, which varies with the changes in the
hardenability of steel used for Internal gears. All in all the results of ten case studies have been
reported.

The Various recommendations to zero defect planning include agenda to lower the quenching
temperature, Raising of the quenching oil temperature, Lowering of the austenizing or carburizing
temperature etc. Implementation of various action schemes lead to reduction of defects to zero levels
(Thareja and Goyal 2005).

Keywords: Quenching, Tractors, heat treatment, carburizing, failures, steel

INTRODUCTION:

Automotive transmission industry uses a large number of case hardened and ground components.
These components are usually made of alloy steel because of the high strength requirements.
Examples of such components are shafts, gears, bearings, bushes etc. Circularity or Roundness is an
important geometric parameter in most of these components. This is because ovality or out-of-
roundness in components (due to distortions) of high speed transmissions can lead to problems like
seizure, vibration, noise and premature failures. A large number of factors during machining in soft
stage, heat treatment and subsequent grinding can lead to this problem. A thorough investigation into
the factors leading to this distortion of form is required. One of the most effected components,
namely Internal Gear is selected for study, to find out and control the process parameters that affect
the distortion of form, leading to ovality or out of roundness.

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*Head, Metallurgical Engineering Department, PEC University of Technology, Chandigarh, 160012, India.
Web site http://www.thareja.com, email prof.pthareja@gmail.com
** M/s TAFE, Parwanoo (H.P), Parwanoo (H.P) Email: mnuvndna@yahoo.co.in

Electronic copy available at: http://ssrn.com/abstract=1541171

PROBLEMS IN MANUFACTURING

DISTORTION

Distortion is a general term encompassing all irreversible dimensional changes. Changes in size or
shape of parts during processing may be either reversible or irreversible. Irreversible changes in size
or shape of steel parts are those caused by stresses that exceed the elastic limit or by changes in
metallurgical structure

Various Methods To Control Heat Treatment Distortions

If one brainwrites options to implement various means to combat Distortion, following seven
methods come to fore. These are:

1. Using Better Grades Of Steel Containing Nickel Like SAE 8620

2. Martempering

3. Austempering

4. Nitriding

5. Use of Local Heating Technique

6. Powder Metallurgy

7. Fixturing During Quenching

Since in the present case the interest revolves around combating them in a case hardening and heat treatment operations
the present study is limited in its scope.

TYPES OF HEAT TREATMENT DISTORTIONS

There are two main types of distortions i.e. size & shape distortion.

I. SIZE DISTORTION DURING HEAT TREATMENT

Size distortion is the result of change in volume produced by change in metallurgical structure
during heat treatment.

¾ First step involves heating part to about 900°C or above to change the matrix to austenite. For
plain carbon steels and low alloy steels, austenizing results in contraction of volume. Extent of
volume contraction depends on C% present. The regression equation of Volume Change on
transformation is given by the following relation:

V sa = - 4.64 + 2.21 (%C) (Eq 1), V sa is volume change in percentage.

Electronic copy available at: http://ssrn.com/abstract=1541171

¾ The second step involves cooling fast enough to cause the austenite to transform to martensite.
The steel expands during this transformation. The amount of expansion is inverse proportional to the
amount of carbon in solution in the austenite:

V am = 4.64 – 0.53 (%C) (Eq 2), Vam is the volume change in percentage

Equations 1 & 2 can be used to calculate net change in dimensions in steel when it is heat-treated.

2. SHAPE DISTORTION:

Second is shape distortion that entails curvature or angular relations such as in twisting, bending
and/or nonsymmetrical changes in dimensions. This is the most troublesome form of distortions
since it is of unpredictable nature. There are many different forms of shape distortion mainly Out of
Round, Taper, Out of Flat, Bending, Buckle, Bowing.

It is pertinent to consider that the hot steel becomes less strong and therefore is susceptible to
buckling or distortion under lesser weight ( sometimes even under its own weight especially when
the sections are disparate.

Following are the factors having influence on shape stability of steels: .

FACTORS THAT EFFECTS SHAPE DISTORTION

2.1 Carburising Temperature

2.1.1 Creep at Higher Temperature

2.1.2 Rapid Heating to Carburising Temperature

2.1.3 High Carburising Temperature

2.2 Quenching Temperature

2.3 Quenchant

2.3.1 The Quenching Process

2.3.2 Effect of Quenchant Temperature

2.3.3 Effect of Agitation

2.4 Fixturing

2.4.1 Handling of Workpiece during Heattreatment

2.4.2 Freedom of Movement

2.4.3 Fixturing during Quenching

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2.5 Tempering Of Heat Treated Component

2.6 Pretreatment To Relieve Stresses during Machining

2.7 Hardenability of Component

2.8 Shot Blasting of Component

MEASUREMENT OF DISTORTION

In our study, distortions in the component are measured in terms of composite error.

Composite Error (C.E.)

As each pair of teeth moves into and out of contact, the centre distance changes by an amount shown
on the dial indicator. This is known as the Tooth to Tooth composite error. This error, when added to
the runout, is known as total composite error.

Gear Roll Tester for Functional Gear Checking, to check Composite Error.

The gear is located from the dowel holes and meshed with the specified Master Gear. The variations
such as Composite Error (C.E.), Tooth to Tooth Error, Dents, Contact Pattern are revealed on the
plunger dial attached to the GRT. With blue oil pastel applied to the teeth of Master Gear, the
contact pattern on the mating component gear can be studied.

Distortions in the component under study, namely Internal Gear

The component faced the problems of excessive distortion of form - namely out of roundness or
ovality, which further increases the Composite Error. In the actual production, the Composite Error
of the component being achieved is upto 0.29mm. These values far exceed the specified limits
leading to a high rate of rejections. Internal gears with composite error of upto 0.20 mm were
accepted on deviation and the rejection is around 3% under deviated condition. High rate of rejection
lead to loss to customer, excessive transmission noise, Safety risk, Inconvenence to the customer &
B/D of machines causing time lost at crucial moments.

EXPERIMENTAL

DETAILS OF THE WORK PIECE UNDER STUDY

The component – namely Internal gear one of many gears, is used in the transmission of an
agricultural tractor. The component is of circular shape having internal splines. It is a big gear with
O.D. maintained at 175 and I.D. 114 + - 0.2 mm. The component is made of case hardening steel
and is case hardened. The specified value of Composite Error on the drawing is 0.12mm. This
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component controls the r.p.m. of tractor. As the gears rotate, these are required to be held to close
tolerances of dimensions and form. The running clearances for the mating gears are of the order of
50 microns.

I. Metallurgical Requirements:

The component is case caburized with following requirements:

Case hardness - 58-63 HRc, Case depth - 0.65-0.85 mm

Jominy value specified for material of Internal gear is J4 – 32 / 39 HRc.

Microstructure: Case: Tempered Martensite with 10% max retained austenite.

II. Material composition

The component is made of IS 20MnCr1, low alloy casehardening steel. The chemical composition of
IS 20MnCr1

ELEMENT PERCENTAGE

CARBON 0.17-0.22%

CHROMIUM 1.00-1.30%

MANGANESE 1.00 –1.40%

SILICON 0.15-0.35%

PHOSPHOROUS 0.035 % Max

SULPHUR 0.035 % Max

HEAT TREATMENT PROCESS DETAILS

. The heat treatment process cycle is as follows:

Charging – The front door of the furnace opens and the charge is fed into the furnace. Therafter the
front door closes.

Heating – The charge is heated to the carburizing temerperature of 927oC. The total time is 180
minutes.

Enriching – Here the carbon percentage of the surface layers is enriched. The carbon potential is
maintained at 1.1 %. The temperature is maintained at 927oC. The enriching or active carburizing
time is 180 minutes.
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Diffusing – Here the carbon is allowed to diffuse into the steel to obtain the desired case depth. The
carbon potential is maintained at 0.85%, diffusion time is 60 minutes

Secondary Hold – In this stage the temperature is allowed to drop to around 800oC. Total time of
this stage is 120 minutes.

Transfer – The charge is then transferred to qunch tank chamber automatically.

Quenching – The charge is lowered into the quench tank for quenching operation. The total delay
specified for this stage is 30 seconds. The charge is held in quench tank for 20 minutes.

Oil dripping – The charge is raised and oil is allowed to drip for 20 minutes. The charge is
thereafter sent for washing.

Recharge – The furnace is then readied for the next charge. The next charge can be fed into the
furnace only after the temperature has reached 930oC and the carbon potential is at least 0.5%

EXPERIMENTAL OBJECTIVES & METHODOLOGY

1. Objective

The objective is to reduce rejections due to high composite error resulting from shape distortion
namely out of roundness and thus

¾ To reduce the rejection cost

¾ To reduce Loss to customer

¾ To reduce risk

¾ To reduce Excessive transmission Noise

¾ To reduce time and inconvenence

2. Options

¾ To re-engineer the existing method of manufacturing and heat treatment

¾ To Incorporate specialised methods of distortion control

3. Route Selected

Re-engineering the existing method of manufacturing and heat treatment by applying quality tools is
the route we have selected since it does not lead to increase in cost of production.

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4. SCHEME

4.1 Experimental

Ten nos. soft internal gears (internal gears finished up to the heat treatment stage) were inspected
and the data was recorded. Suitable permanent markings were made to track the components and
correlate the results before and after the heat treatment by changing various heat treatment
parameters.

Various experiments to be carried out were designed w.r.t following imperatives:

4.2 BREAK DOWN OF PROBLEM AND ANALYSIS

1. To observe the effect of heat treatment on the distortions of internal gear

2. To observe the effect of orientation of component during heat treatment on distortions.

3. To observe the effect of lower carburizing temperature during heat treatment on distortions.

4. To observe the effect of lower quenching temperature during heat treatment on distortions.

5. To observe the effect of higher quenching oil temperature during heat treatment on distortions.

6. To observe the effect of shot blasting (s.b.) for de-scaling on the distortions

7. To observe the effect of change in the process sequence on the distortions in internal gears.

8. To observe the effect of change in hardenability on the distortions in internal gears

EXPERIMENT NO. 01

TO OBSERVE THE EFFECT OF HEAT TREATMENT ON DISTORTIONS

Effect of heat treatment on distortion

SAMPLE NO.
1 2 3 4 5 6 7 8 9 10 AVG.
PARAMETERS

BEFORE C.E
0.02 0.04 0.01 0.02 0.06 0.05 0.05 0.05 0.02 0.02 0.037
HT

AFTER C.E
0.24 0.27 0.29 0.12 0.17 0.11 0.27 0.15 0.26 0.18 0.226
HT

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RESULTS & ANALYSIS

It can be concluded that the heat treatment process is mainly responsible for the distortions in the
internal diameter of the internal gears when loaded in their normal vertical position.

EXPERIMENT NO. 02

TO OBSERVE EFFECT OF ORIENTATION OF COMPONENT DURING HEAT

TREATMENT ON DISTORTIONS.

Effect of components resting horizontally

SAMPLE NO. 1 2 3 4 5 6 7 8 9 10 AVG.

PARAMETERS

BEFORE C.E
0.03 0.03 0.04 0.02 0.02 0.02 0.05 0.03 0.04 0.03 0.031
HT

AFTER C.E
0.25 0.24 0.24 0.12 0.11 0.09 0.26 0.25 0.25 0.12 0.193
HT

RESULTS & ANALYSIS

This clearly shows that orienting the components in a more stable and balanced horizontal position
does have a beneficial effect on the distortions produced during the heat treatment. At this higher
temperature the material loses most of its strength. Prolonged exposure to such temperature may
cause the component to creep under its own weight unless it is oriented in a manner that reduces this
chance.

EXPERIMENT NO. 3

TO OBSERVE EFFECT OF LOWER CARBURIZING TEMP. DURING HEAT

TREATMENT ON DISTORTIONS.

Effect of decrease in carburising temperature

CARB. TEMP. °C 930 925 920 915 910

AVERAGE C.E. 0.238 0.230 0.226 0.215 .208

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RESULTS & ANALYSIS

The observations show that there is a reduction in level of distortions as the carburizing temperature
is lowered. This can be explained as follows: Due to the increased temperature during carburizing,
the surface austenite grows at a higher rate than the core austenite. This excessive growth can lead to
two potential problems. First, during quenching larger austenite grain can result in a less uniform
expansion leading to distortion. Secondly a larger grain size of austenite can result in a larger
amount of retained austenite after quenching. The retained austenite transforms at a later stage due to
temperature or stress considerations leading to further distortions. At lower carburizing temperatures
austenite grows at a slower rate and the problems listed above are reduced. In addition the rate of
temperature increase can be reduced, leading to lower temperature differential between the case and
the core. This results in lower thermal stresses and reduced distortions.

EXPERIMENT NO. 5

TO OBSERVE EFFECT OF LOWER QUENCHING TEMP. DURING HEAT TREATMENT

ON DISTORTIONS.

Effect of decrease in Quenching temperature

QUENCHING TEMP.
800 790 785
°C

AVERAGE C.E. 0.226 0.206 0.200

RESULTS & ANALYSIS

The observations show that there is reduction in level of distortions when the internal gears are
subjected to quenching at a lower quenching temperature as compared to the existing heat treatment
process. This can be explained as follows: A decrease in the quenching temperature would result in a
slower cooling rate and a smaller temperature gradient in the component during quenching. After
carburizing the component has a higher carbon content near the surface. This lowers the Ms
temperature. It is desired that the transformation of the core austenite take place prior to that of the
surface. This is because as the case austenite transforms to martensite, it expands. But since the core
has already transformed it resists the expansion of case. This induces desirable compressive stresses.

Lower quenching temperature will result in slow cooling rate. If the quench rate is too steep and the
surface temperature falls below the Ms temperature before that of core, then the case austenite will
transform before that of the core austenite. Resultantly the core volume expansion would be resisted

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 by the hard surface causing tensile residual stresses, distortion, decreased fatigue life and possibly
quench cracking.

EXPERIMENT NO. 6

TO OBSERVE THE EFFECT OF HIGHER QUENCHING OIL TEMPERATURE ON

DISTORTIONS

Effect of decrease in quenching oil temperature

QUENCHING OIL
80 90 100
TEMP. °C

AVERAGE C.E. 0.226 0.211 0.202

RESULTS & ANALYSIS

An increase in the quench oil temperature would result in a slower cooling rate and a smaller
temperature gradient in the component during quenching. Also the rate of cooling in convection stage
will become slower as the temperature of the bath increases. This is advantageous because a slower
rate of cooling through austenite to martensite transformation generally reduces the tendency of
distortion or cracking.

EXPERIMENT NO. 7

TO OBSERVE EFFECT OF SHOT BLASTING (S.B.) FOR DE-SCALING, ON

DISTORTIONS.

SAMPLE NO.
1 2 3 4 5 6 7 8 9 10 AVG.
PARAMETERS

BEFORE S.B. C.E 0.28 0.27 0.27 0.29 0.12 0.12 0.17 0.26 0.27 0.18 0.223

AFTER S.B. C.E 0.24 0.27 0.29 0.12 0.17 0.11 0.27 0.15 0.26 0.18 0.226

RESULTS AND DISCUSSIONS

The observations show that in this particular application, shot blasting appears to have little effect on
the distortions caused in the internal gears. As the objective is just to de-scale the component a lower
peening intensity is used. The stresses, which may be caused by this operation, are not high enough
to cause any significant distortions in the component.
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 EXPERIMENT NO. 8

I TO OBSERVE THE EFFECT OF CHANGE IN THE PROCESS SEQUENCE WITH

MILLING, DRILLING, DOWELLING, REAMING OPERATION BEING CARRIED OUT
BEFORE BROACHING AND THE INTRODUCTION OF INTERMEDIATE STRESS
RELIEVING TREATMENT

Effect of stress releiving on distortions

SAMPLE NO.
1 2 3 4 5 6 7 8 9 10 AVG.
PARAMETERS

BEFORE C.E
0.24 0.27 0.29 0.12 0.17 0.11 0.27 0.15 0.26 0.13 0.226
HT

AFTER C.E
0.26 0.24 0.26 0.24 0.11 0.10 0.11 0.16 0.25 0.25 0.198
HT

RESULTS & ANALYSIS

The turning and milling processes generally produce tension near surface and compression below.
The magnitude of turning stresses depends on such variables as the cutting tool geometry and feed
and speed during the turning process. The depth of residual stresses both during turning and milling
is on the order of 0.25 mm. These residual stresses if high enough in value can cause the component
to go out of shape during heat treatment process. The residual stresses during machining, even
though not high enough to cause distortion at room temperature may get relieved during heat
treatment causing distortion.

EXPERIMENT NO. 9

TO OBSERVE EFFECT OF CHANGE IN HARDENABILITY ON DISTORTIONS IN

INTERNAL GEARS.

Effect of hardenability on distortions

HARDENABILITY J4 – 39 HRC J4 – 36 HRC J4 – 33 HRC

AVERAGE C.E. 0.240 0.141 0.141

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 RESULTS & ANALYSIS

The observations show that significant improvement in the Composite error is achieved after heat
treatment with the proposed changes in the hardenability of steel used for Internal gears. Doordarshi
and Thareja 2006) while experimenting with Hardenability w.r.t weldability concluded that
importance of heating and cooling rate on to cracking resistance was commensurated on carbon
equivalent. In case carburised components where core hardness plays a very crucial role in imparting
toughness to the component, too high a jominy value can result in high core hardness which in turn
changes the stress distribution pattern and can lead to distortion and poor mechanical properties.
Jominy values specified earlier were J4 – 32 / 39, now it has been changed to J4 – 30 / 36. Rejections
with this modification have reduced to quite a large extent.

EXPERIMENT NO. 10

TO OBSERVE OVERALL EFFECT OF MODIFICATIONS CARRIED OUT IN THE

PROCESS SEQUENCE ON COMPOSITE ERROR OF INTERNAL GEARS.

Overall effect of heat treatment modification

SAMPLE NO.
1 2 3 4 5 6 7 8 9 10
PARAMETERS

BEFORE C.E
0.02 0.02 0.02 0.02 0.02 0.04 0.04 0.04 0.04 0.04
HT AVG.

AFTER C.E
0.04 0.09 0.06 0.06 0.02 0.11 0.07 0.06 0.09 0.06
HT

SAMPLE NO.
11 12 13 14 15 16 17 18 19 20
PARAMETERS

BEFORE C.E
0.06 0.06 0.06 0.06 0.06 0.08 0.08 0.08 0.08 0.08 0.05
HT

AFTER C.E
0.04 0.09 0.12 0.06 0.09 0.13 0.07 0.12 0.13 0.09 0.80
HT

RESULTS & ANALYSIS

The observations show that significant improvement in the Composite error in the internal gears is
12
achieved with the proposed changes in the manufacturing process. Hence with the changes in the
manufacturing process parameters, the Composite error due to ovality or out of roundness observed
in the Internal gears has been brought under control and within the specified values.

SUMMARY OF RECOMMENDATIONS

In the present work experiments were conducted in which these parameters were varied and
controlled with the objective of minimizing the distortions. The following conclusions can be drawn
from the present work:

1. Present heat treatment cycle is responsible for distortions and thus high Composite error in case
hardened Internal gear

2. The orientation of the component during heat treatment also affects the distortions in the
component. This is because during heat treatment, strength of the component is very low at elevated
temperature. This may result in creep under the weight of the component resulting in distortion.
Hence it is important to properly orient the component or support it.

3. Lowering of the austenizing or carburizing temperature has a positive affect on the minimizing
of distortions during heat treatment. This is because at lower carburizing temperatures, austenite
grows at a slower rate. The larger austenite grain size is associated with two problems. First, during
quenching larger austenite grain can result in a less uniform expansion leading to distortion.
Secondly a larger grain size of austenite can result in a larger amount of retained austenite after
quenching. The retained austenite transforms at a later stage due to temperature or stress
considerations leading to further distortions.

4. Lowering of the quenching temperature also has a beneficial effect in minimizing the distortions
observed during heat treatment. An decrease in the quenching temperature results in a slower
cooling rate and a smaller temperature gradient in the component during quenching. This results in
lesser thermal stresses in the component during quenching resulting in lower distortions.

5. Raising of the quenching oil temperature also has a beneficial effect in minimizing the
distortions observed during heat treatment. An increase in the quenching oil temperature results in a
slower cooling rate and a smaller temperature gradient in the component during quenching. This
results in lesser thermal stresses in the component during quenching, resulting in lower distortions.

6. The introduction of stress relieving before the finishing cuts are made to the component also
result in reduction of distortion. This is because the internal stresses caused by the previous
machining operations are relieved during heat treatment. This results in change of dimensions. If
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however the stresses are relieved before final machining cuts are made, the changes in the
dimensions after heat treatment are minimized.

7. Significant improvement in the Composite error is achieved after heat treatment with the changes
in the hardenability of steel used for Internal gears. In case carburised components where core
hardness plays a very crucial role in imparting toughness to the component, too high a jominy value
can result in high core hardness which in turn changes the stress distribution pattern and can lead to
distortion and poor mechanical properties.

CONCLUSION

It was seen that the heat treatment defects could be avoided by meticulous planning and the culture
to do First time Right.

The process may be investigated in right Ernest and the parameters strictly applied using the Quality
systems approach.

REFERENCES

1. Thareja P, Goyal Mannu, (2005), “zero defect planning of case hardened transmission gears- a case
study”, Proceedings of National Conference on Advances in Manufacturing Technology, Mechanical
Engineering Department, NITTTR, Chandigarh, India November 09-11, 2005

2. Thareja Priyavrat (2008), ‘ Extending Competencies To Peaceful Uses By Innovation And Culture, ”
15th EDIC National Conference on Advances on Frontiers of Entrepreneurship, From Research to
Results, National Institute of Technical Teachers’ Training and Research., Nov 17-19, Chandigarh.

3. Thareja P, (2006), “Transforming a Foundryman to Zero Defect’, FOUNDRY, Vol XVIII, No 1,

Jan//Feb 2006.

4. Thareja P(2007), Why Go-Get Standardized In A Quality Wide Web? Vol V, No 8, Aug, 2007.

5. Doordarshi, Thareja P, (2006), “The Hardenability- Weldability Relationship”, International conference

on manufacturing Systems, BBSEBC, Fatehgarh Sahib, Sept 06

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