MATS Training

Brief Information about the company

MOTHERSON ADVANCED TOOLING SOLUTIONS LIMITED (MATS) is a significant part in the metal division of the world-renowned group SAMVARDHANA MOTHERSON. Motherson Advanced Tooling Solutions Limited (MATS) was incorporated by acquiring Broaches & GCT business from Dagger-Forst Tools Limited wef 01ST June 2009. MATS are pioneers in manufacture of high quality broaches and HSS Gear Cutting Tools in India. We have 4 manufacturing sites located in Western India fully equipped with state of the art manufacturing and testing facilities including in-house Heat Treatment facilities. All plants are ISO 9001: 2000 certified. We are market leaders in India & also have a considerable market share in USA, Europe, RSA, Iran, South East Asia, Australia etc. Reputed automobile manufacturers like GM, Ford, Hyundai, Eicher, Hero Honda, Suzuki and Yamaha are our valued customers along with auto component manufacturers like Dana Spicer, Fair Field, GKN and Graziano Transmissions.

Products made in MATS

1. 2. 3. 4. Hobs Broach (internal) Broach (flat) Gear Shaver

What is broaching ?
Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There are two main types of broaching: linear and rotary. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. Linear broaches are used in a broaching machine, which is also sometimes shortened to broach. In rotary broaching, the broach is rotated and pressed into the workpiece to cut an axis symmetric shape. A rotary broach is used in a lathe or screw machine. In both processes the cut is performed in one pass of the broach, which makes it very efficient. Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include circular and non-circular holes, splines, keyways, and flat surfaces. Typical workpieces include small to medium sized castings, forgings, screw machine parts, and stampings. Even though broaches can be expensive, broaching is usually favored over other processes when used for high-quantity production runs.[1]

ROUND BROACH
Application: Internal :- Round, Keyway, Straight or Involute Form, Serration & Special Internal profile. Design Capabilities:Any Special Profile requirements. Material:M2, M35, M3 Type II, M42, ASP23, ASP30, CPM T15, CPM M4 Size Range:Round & Spline Dia. 15mm 250mm, Length upto 2000mm Flat width 4mm to 200mm Accuracy:Within 0.01mm

Process followed
Raw material cutting Pilot and taper turning Teeth cutting Spline milling Heat treatment Centre grinding Rough cylindrical grinding Sharpening (rough)

Soft Machining

Grinding process ( Profile generation)

Gullet Finish cylindrical grinding Sharpening (finish) Profile grinding Round and flat holding Nicking Inspection and trial Marking and packing

Grinding process

Flat broach
Application: External :- Connecting Rods, Turbine Blades, Shifter Forks, Steering Racks. Design Capabilities:Any Special Profile requirements. Material:M2, M35, M3 Type II, M42, ASP23, ASP30, CPM T15, CPM M4, Size Range:Round & Spline Dia. 15mm 250mm, Length upto 2000mm Flat width 4mm to 200mm Accuracy:Within 0.01mm

Process Followed
Raw material cutting Width and thickness milling Taper milling Teeth milling machining Extra material removing Milling pull end / rear end Heat treatment

Soft

Grinding bottom width Grinding top , teeth size and taper Grinding of angle block and keyway Grinding profile Profile Holding making Nicking Back off Inspection Packing

What is hobbing ?
Hobbing is a machining process for making gears, splines, and sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting process for creating spur and helical gears and more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.

Hob
Module: 0.5 M 20 M; Dia. : 50 to 250 mm (also DP series) Start: Single or Multi Start. Accuracy: AA, A, B & C (as per DIN 3968) Forms : Non-Topping, ST, T, finishing, preshaving, pre- grinding, with or without protuberance, tip relief, full fillet, etc. Material : M35, M42, ASP 30, ASP 2052, etc. Each Item tested on Hoffler Gear Tester.

Process followed
Raw material cutting Facing Drilling Boring , Recessing Rough turning Finish turning Keyway cutting Thread cutting Gash milling Releving

Soft machining

Heat treatment Face grinding Proof diameter grinding Bore grinding Sharpening of cutting edge Profile grinding Nicking Marking Inspection

profile making

What is shaving
Gear shaving is basically a finishing operation. This takes place after the operations of roughing with a hob or cutting with a shaper cutter is over. The Shaving process consists of the removal of tiny particles of metal from a gear teeth's working surface. Gear shaving produces fine hairlike chips. The cutter comes in the form of helical gear. It has special serrations in the flank area of a gear teeth. These serrations act as the cutting edges.

Shaving cutter
Improved surface finish of flanks and accuracies of profile Produce high accurate gear at low cost. Range : 170 mm to 260 mm PCD. Material : M2 & M3 (II) type of HSS material. Also carry out resharpening with profile correction Module : 0.8 M to 6.35 M. Special design for lower than 1.50 modules. Used for finishing operation of Gears for Automobile Transmission & other similar Engg. Industry. Each Item tested on Hoffler Gear Tester.

Process followed
Raw material stress relieving Drilling Boring Chamfering Grooving Facing Turning Rotary grinding Soft bore grinding

soft machining

O D grinding Hobbing Root milling Serration Keyway cutting Heat treatment Rotary grinding Grinding bore (finish) Profile grinding OD grinding Inspection

soft machining

profile making