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To Arrive At Solution for Profile Distortion Problem Encountered During Heat Treatment Process of Gear Manufacturing Using Root Cause Analysis

Raveen John, Dr. Y .S. Varadarajan , Paul Pereira

Gear Box, assemblies and hence quality of its components(referring to gears) play a vital role during transmission mechanism. Many issues have occurred and still do occur during the processing of gears especially in areas of Hobbing , Shaving, Heat Treatment processes, etc and best trials have been carried out so as to attain authentic solutions to the complexities occurred. Oerlikon Fairfield- a gear manufacturing MNC successfully uses Root Cause Analysis Techniques( PDCA cycle, Cause and Effect Diagram with Shainin Technique combination), DMAIC quality improvement Methodology in order to solve the problems encountered during part processing . The present paper deals with Profile fall/distortion problem occurring after heat treatment process during new development of helical gear. Modern gearboxes are characterized by high torque load demands, low running noise and compact design. In order to fulfill these requirements, profile specifications have to be tightly controlled. Current problem being one of major quality issues is resolved and controlled by using a combination of Cause and Effect Diagram with Shainin Technique and DMAIC-6 sigma break through methodology. Tool modifications being considered as final resort and hence implementation of modifications of shaving cutter during shaving stage (a pre heat treatment process) helped in achieving the required profile trace within the required post heat treatment process specifications.