Abstract
This paper focuses on the input shaft of a gearbox assembly from a well-known automobile company. The company was facing a problem of noise and vibrations in the reverse gear section of the input shaft. The problem was the formation of nick at the gear root of the reverse gear. A nick is plus material anywhere on the part. The reverse gear section undergoes two machining operations, viz. shaping and shaving, and therefore, these two processes are focused in this work. The experiments are designed as per Taguchi’s L9 orthogonal array with two replications of each experiment. Total 27 experiments were carried out for the process optimization by varying three control factors, viz. cutter span width, shaping over ball diameter, and shaving over ball diameter, and by considering nick value as the response. After the analysis, we found that the response is best when cutter span width is 69.450 mm, shaping over ball diameter is 33.636 mm, and shaving over ball diameter is 33.450 mm. The optimum condition for the best results is calculated and validated.
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Acknowledgements
Authors are thankful to authorities and staff of Fiat India Automobiles Limited, Pune, for providing the facilities and necessary support for experimentation.
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Sapkal, S.U., Bhilawade, T.A. (2020). Elimination of Nick Defect by Process Optimization for Input Shaft Reverse Gear Section. In: Venkata Rao, R., Taler, J. (eds) Advanced Engineering Optimization Through Intelligent Techniques. Advances in Intelligent Systems and Computing, vol 949. Springer, Singapore. https://doi.org/10.1007/978-981-13-8196-6_63
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DOI: https://doi.org/10.1007/978-981-13-8196-6_63
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