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Industrial Visit Report YCCE, Nagpur

CHAPTER: 1

Industrial Visit Report


of
KINETIC GEARS, MIDC, NAGPUR

 Details of Visit
 Date: 30 July 2018
 Place: Kinetic Gear ,MIDC, Nagpur.
 Address: E 19/1 MIDC Industrial Area, Hingna Road,
Nagpur- 440028.
 Time: 10:00 AM to 3:00 PM
 Faculty Coordinators: Prof. S. S. Akant, Prof. Ms. D. N. Kashyap.
 Visitors: Students of 5th semester Mechanical Engineering Department.

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Industrial Visit Report YCCE, Nagpur

 INTRODUCTION

Kinetic Gears commenced its operations in the year 1980 in Nagpur


under the guidance of Mr. Vishram Jamdar as Managing Partner.
Progressively emerged as the most reliable gear manufacturing unit,
housing best in class machines tools, heat treatment and
reassembly facilities for gear boxes. The unit picked up well and
started supplying Hi-tech Gears to Eicher Tractor, Mahindra &
Mahindra, Ordnance Factory, Ashok Leyland Hindustan Aeronautics
and State Electricity boards etc. The imported gears for different
machines developed by the unit for Ordnance Factory, has given a
Certificate Of Import Substitution to Kinetic Gears. Mr. Vishram
Jamdar was also felicitated at the hands of RBI Governor by MSFC,
as one of the Best Entrepreneurs of Maharashtra.

Integration of system like ISO 9001:2008 for all its


processes is deep rooted. Periodic reviews of the set targets &
objectives are carried out in Management Review Meetings. Kinetic
Gear’s culture and value system are based on integrity,
transparency, mutual trust, excellence oriented performance. Kinetic
Gears believes that the employees are the most valuable dynamic
asset of the organizations. Value system and principle based
approach of the leadership have brought in good attitudinal changes
in employees to contribute fullest of their potentials. To sustain in the
market, Kinetic Gears constantly upgrading it’s facilities, equipment’s
and technologies since inception of gear manufacturing in the year
1980. In short KG will always strive to achieve business excellence
through quality work and technology up gradation.

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Industrial Visit Report YCCE, Nagpur

 COMPANY PROFILE

 Kinetic Gears : Partnership (Family owned)


 Nature of ownership : Sole Proprietorship (Individual)

 Number of employees : 15-24 People


 Nature Of Business : Manufacturer / Supplier
 Annual Turnover : Rs. 50 Lakh – 1 Crore
 Year of Establishment : 1982

 Address : E 19/1 MIDC Industrial Area Hingna


Road Nagpur - 440028
 Emails : kineticgears@gmail.com
shree@kineticgears.in
 Web : www.kineticgears.in
 Phone Nos. : +91 7104-237447 , +91 7104-237634
 Fax Nos. : +91 7104-237388
 Contact Persons : Vishram Jamdar - +91 9923432747
Shree Jamdar - +91 9823290006

 MISSION & VISION


Mission

“Our Mission is to adequately empower individual worker,


supervisor, staff to significantly increase his Performance
Capability in order to achieve the desired goal through mutual
understanding and centered leadership.”

Vision

“To produce and supply defect free Gears, Gear Boxes &
Machined Components at the most competitive price as and when
required by our Valued Customers.”

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Industrial Visit Report YCCE, Nagpur

 ORGANIZATIONAL STRUCTURE

Fig 1.1: Organizational structure

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Industrial Visit Report YCCE, Nagpur

 COMPANY’S VALUED CUSTOMER

1. Ashok Leyland Ltd. Bhandara, Ennore , Pantnagar


2. Ordnance Factory Nagpur, Bhandara
3. M.S.P.G.C.L. ( Power Generation Co. )
4. W.C.L. ( Coal Sector )
5. Bhilai Steel Plant , Sunflag Iron & Steel.
6. Mahindra & Mahindra Ltd.
7. Indorama Textile, Spintex, Morarjee Mills
8. Hindustan Aeronautic Ltd. Bangalore
9. Lemken India Agro Equipment’s Pvt. Ltd.
10. Ford India Ltd
11. Uni Deritend Ltd. Tumsar

 COMPANY’S APPROACH

1. Customer delight through …

a. Delivery of products with quality and reliability.

b. 100 % on time delivery.

c. Cost competitiveness.

2. Ensuring safe and healthy working.

3. Total involvement of Employees through Suggestion, CFT &


Continual Improvements.

4. Robust Processes.

5. Result Orientation.

6. Lean Manufacturing.

7. Use of modern manufacturing techniques.

8. Continual improvement,

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Industrial Visit Report YCCE, Nagpur

 PRODUCTS MANUFACTURED

1) Spur Gears: 2) Spiral Bevel Gear:

3) Worm Gears: 4) Reduction Gear:

5) Gear Clusters : 6) Gear Shafts :

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Industrial Visit Report YCCE, Nagpur

7) Gear Sprockets: 8) Big Washer:

9) C M Gear: 10) Big Bearing Plate :

11) Fan Shaft: 12) Techno Pinion:

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Industrial Visit Report YCCE, Nagpur

13) Screwed Bush: 14) Pluse Disc:

15) Detent Plunger: 16) OD Seclector Plate:

17) Seclector Plate: 18) Clutch Plate:

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Industrial Visit Report YCCE, Nagpur

19) Rev. Idler Gear: 20) Slow Group Sub Assembly:

21) Cam: 22) Shift Finger:

23) Trigger Wheel: 24) Selector Arm:

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Industrial Visit Report YCCE, Nagpur

25) Leaver: 26) Speedo Worm:

27) G.S. Finger: 28)

29) 30)

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 MACHINES TOOLS & TESTING EQUIPMENT’S

A. VERTICAL MACHINING CENTER :

The process of milling uses a specialized rotary cutting tool to remove


material from a workpiece surface. The process can be used for cutting
and creating details, such as holes or notches, as well as for sculpting a
three dimensional piece.

Unlike drilling or traditional cutting, the tool in a mill advances


perpendicularly to a workpiece on a dedicated axis, performing countless
unique, small cuts to remove material from a surface in chips.

With Computer Numerical Control (CNC) technology, machinists and


engineers can control vertical milling machine operations using sensitive
computer systems. These systems collect design information directly from
drawings and models in CAM or CAD software, which is converted into
codes (NC code, G-code, and ISO code) and then translated into
operational commands through the system.

A CNC vertical mill machine has cylindrical cutters oriented vertically on a


spindle axis. This is especially useful for plunge cuts and drilling; these
tools are considered to be the best for diesinking applications. With CNC
technology, the tools in some vertical machining centers can be
manipulated on up to five axes for the fabrication of custom shapes, slots,
holes, and details in three-dimensional parts.

1) Jyoti VMC 850 :

Jyoti VMC 850 – 1 No.


Table Size 1000mm X 530mm
Capacity Z = 820mm , X & Y = 510mm

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F-1.2 :-Jyoti VMC 850

2) Jyoti Make VMC 850 :


Jyoti Make VMC 850 with 24 ATC – Qty 1 No.
Jyoti Make VMC 640 with APC & 24 ATC- Qty 1 No.
Capacity Z=810mm , X & Y = 510 mm
With Delcam programming facility.

F-1.3: Jyoti Make VMC 850

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3) Jyoti VMC PX 10 & Jyoti VMC PX 40 :

Jyoti VMC PX 10 – 1 No.


Table Size 660mm X 630mm
Capacity Y = 410mm , X & Z = 510mm

Jyoti VMC PX 40 – 2 Nos.


Table Size 915mm X 450mm
Capacity Z = 760mm , X & Y = 510mm

F-1.4: Jyoti VMC PX 10 & Jyoti VMC PX 40

B. CNC TURNING CENTER :


Some view Lathes as the only universal CNC Machine tool because a
lathe can make all of the parts needed for another lathe. A lathe spins the
workpiece in a spindle while a fixed cutting tool approaches the workpiece
to slice chips off of it. Because of this geometry, lathes are ideal for parts
that have symmetry around some axis that could be chucked up in the
spindle.

CNC Lathes have at the very least the ability to drive the cutting tool
under g-code control over 2 axes, referred to as X and Z. They may have
a considerable amount of other functionality as well, and there are many
variations on lathes such as Swiss Lathes.

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The act of cutting a workpiece on a lathe is called "Turning".

Due to technological advancements, CNC lathes are quickly replacing


some of the older and more traditionally used production lathes, such as
the multi-spindle. CNC lathes come with a number of benefits. They can
be easily set up and operated. They offer tremendous repeatability, along
with top-notch accuracy in production.

A CNC lathe is typically designed to utilize modern versions of carbide


tooling and processes. A part can be designed for customization, and the
machine’s tool paths are often programmed using the CAD or CAM
processes. However, a programmer can manually design a part or tool
path as well. The resulting coded computer file is then uploaded to the
CNC machine, and the machine will then automatically produce the
desired parts for which it was programmed to design.

1) Jyoti DX 200 :

CNC Turning Centers: 11 Nos.


Capacity:- Ø 350mm x 800mm Length

F-1.5: Jyoti DX 200

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F-1.6: Jyoti DX200

C. GEAR HOBBING MACHINE :


Hobbing is a machining process for gear cutting, cutting
splines, and cutting sprockets on a hobbing machine, which is a
special type of milling machine. The teeth or splines are
progressively cut into the work piece by a series of cuts made by a
cutting tool called a hob.

Hobbing Machines: 8 Nos.


Capacity : Ø10mm to Ø1600mm & from 1.5DP to 52DP

F-1.7: Hobbing Machine

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D. SPM Vertical Broaching Machine :

Vertical broaching refers to the type of machine that is


used to broach a piece part. Vertical broaching is typically used to
cut external slots, shapes, and forms. Each application of vertical
broaching usually consists of a custom made tooling package, and
a fixture to hold and secure the piece part. An example of a vertical
broaching application would be cutting a deep slot in a large
industrial valve stem.
SPM Vertical Broaching Machine 3VT / 6VT – 1 No. each
Maximum Pulling Force – 3000 kg / 6000 kg Broach Stroke –
1000mm / 1200mm Work Table – 325mm X 680mm both

F-1.8: SPM Vertical Broaching Machine

E. Cylindrical Grinder :

The cylindrical grinder is a type of grinding machine used to shape


the outside of an object. The cylindrical grinder can work on a
variety of shapes, however the object must have a central axis of

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rotation. This includes but is not limited to such shapes as a


cylinder, an ellipse, a cam, or a crankshaft.
Cylindrical Grinder – 2 Nos.

F-1.9: Cylindrical Grinder

F. GEAR SHAPING MACHINE :


Gear shaping is a machining process for creating teeth on
a gear using a cutter. Gear shaping is a convenient and versatile method
of gear cutting. It involves continuous, same-plane rotational cutting of
gear.

F-1.10: Gear Shaping Machine

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G. SURFACE GRINDING MACHINE :

Surface grinding is used to produce a smooth finish on flat


surfaces. It is a widely used abrasive machining process in which a
spinning wheel covered in rough particles (grinding wheel) cuts
chips of metallic or nonmetallic substance from a work piece,
making a face of it flat or smooth.

Saddle type Surface Grinders : 2 Nos.

F-1.11 surface grinding machine

H. MILLING MACHINE :

A milling machine is a machine tool in which a


horizontal arbor or vertical spindle rotates a cutting tool above a
horizontal table, which is used to move a work piece. A milling
machine will shave off small sections of the metal until the final
product is produced.

Milling Machines (Bridgeport, Batlibouy, WMW)

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F-1.12: Milling machine

I. SLOTING MACHINE :
A machine tool with a vertically reciprocating planning tool used
for making a mortise or shaping the sides of an aperture.

F-1.13: slotting machine

J. MISCELLANEOUS :
 Centre less Grinders (up to Ø 150 x 300mm) Qty: 2 Nos
 Reishauer Gear Profile Grinding Machine.
 Red Ring Gear Shaving Machine.
 Conventional Lathes to turn up to 2 meters X 4000mm Length
 Drilling machines (Pillar & Radial)
 Tooth rounding
 Chamfering Machine up to 8 Module.

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 TESTING EQUIPMENT’S
A. Dynascan Profile Projector with Geometric Measurement
System DGMS3 :
Features :
Dimensions, tolerances, constructions, comparison with CAD master
drawings for SPC analysis.

Measurements presented as drawings, bar charts, graphs and


spreadsheets. Measurement of first part automatically becomes a
stored program for repetitive inspections.

User friendly and can be mastered quickly on the shop floor,


increasing productivity and accuracy.

Reports:

Red / Green color coded part drawings.

Pass / fail results.

Graphs and Bar Charts.

F-1.14: Dynascan Profile Projector

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B. Lead & Profile Checking Machine :

F-1.15: LEAD & PROFILE CHECKING MACHINE

C. Gear Roll Testing Machine :

F-1.16: GEAR ROLL TESTING MACHINE

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 Production process / line of spur gear manufacturing :


Illustrated here is a typical process of making spur gears

Raw Material

Raw materials bought from material suppliers are kept in stock.


The materials are six meters in length

Slicing for required length


using machine saw

The materials are cut to size.

Finishing the side faces


with
cylindrical Grinder

The sides surfaces are grinded

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Turning for Required


Blank Dimension
Using Lathe machine

With a lathe, a cut work piece is shaped into a gear blank.

Internal Spline Broaching

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Gear Generation Process


(Hobbing)

Gear cutting is done with a gear hobbing machine.

Gear Finishing Process


(Shaving)

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Black Oxide Finish-


Oxynit Process
(Sursulf Nitriding )

The black oxide finish is somewhat effective in preventing rust.

Packaging

To ensure delivery in good condition each and every spur gear is


individually packaged.

Raw materials (bar) of 20MnCr5, Cast Iron grade 35, Hylam


were purchased for the nearest dimension, sliced using metal cutting
machine saw for 25 mm thickness, turned to 87.86 mm diameter and faced
to 20 mm thickness. The produced gear blank with required dimension is
machined using gear generation process (Hobbing). Shaving process is
used for the finishing of gear teeth. As a final stage inspection of finished
gear was carried out. The manufactured solid 20MnCr5 spur gear is shown
in figure.

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 PLANT LAYOUT OF KINETIC GEARS

F-1.17: Plant Layout of Kinetic Gear

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 CONCLUSION

 We conclude that, while going through the entire industrial visit,


the co-operation is found to be very well organized, developed
& most ideal industry in every walk of its production,
administration & management aspects.
 We extend our heartiest thanks to Kinetic Gear, MIDC,
Nagpur for making 30th July 2018 a day to cherish for some of
the lucky students like us who are honored with your humble
gesture to get an opportunity to visit such an esteemed
organization.
 We also want to thank to director Mr. Vishram Jamdar Sir of
Kinetic Gear and to Faculty coordinator Prof. S. S. Akant Sir ,
Prof. Ms. D. N. Kashyap Ma’am for coordinating the visit.

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Industrial Visit Report YCCE, Nagpur

CHAPTER: 2

Industrial Visit Report


of
HEAT TREAT WELL, MIDC, NAGPUR

 Details of Visit

 Date: 30 July 2018


 Place: Heat Treat Well ,MIDC,Nagpur
 Address: E 12/1 MIDC Industrial Area Hingna Road Nagpur- 440028.
 Time: 10:00 AM to 3:00 PM
 Faculty Coordinators: Prof. S. S. Akant, Prof. Ms. D. N. Kashyap
 Visitors: Students of 5th semester Mechanical Engineering Department

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 INTRODUCTION

Fully equipped Heat treatment shop approved by Ashok Leyland &


Mahindra & Mahindra with following facilities:

 Gas Carburizing
 Through Hardening
 Induction Hardening
 Nitriding
 PPT Hardening for non-ferrous
 ISO Thermal annealing
 Normalizing
 Oxynit process – Sursulf Nitriding

 COMPANY PROFILE

 Heat Treat Well : Partnership (Family owned)


 Nature of ownership : Sole Proprietorship (Individual)

 Number of employees : 15-24 People


 Nature Of Business : Manufacturer / Supplier
 Annual Turnover : Rs. 50 Lakh – 1 Crore
 Year of Establishment : 1982

 Address : E 12/1 MIDC Industrial Area Hingna


Road Nagpur - 440028
 Emails : heattreatwell@gmail.com
 Phone Nos. : +91 7104-237447 , +91 7104-237634
 Fax Nos. : +91 7104-237388, 232807
 Contact Persons : Vishram Jamdar - +91 9923432747
Shree Jamdar - +91 9823290006

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 ORGANISATION STRUCTURE

F-2.01:Organizational Structural

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 MACHINE AND TESTING EQUIPMENT’S

A. GAS CARBURISING FURNACE :

Gas carburizing is a surface-hardening process that is carried out


at a high temperature, usually above 925°C. Carburizing is essentially the
addition of carbon at the surface of low carbon steels at appropriate
temperatures. Case hardening is achieved with the quenching of the high
carbon surface layer that has a good fatigue and wear resistance.

F-2.02: Gas Carburizing Process

 Type of Equipment : Electrically Heated Pit type Energy Saving


Gas Carburizing Furnace.
 Useful Retort Size : 600 Dia × 1200 h
 Power Rating : 36 KW
 Power Supply : 3 Phase , 415 V ,AC ,50 Hz.
 Operating Temp : 930°C
 Max. Temperature : 950°C

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 Insulation : The Furnace is insulated with high density


Ceramic fiber block of 250 mm thick, the density of the fiber will be
of 128 kg/m.cu.
 Thermocouple : 2 No’s Cr / Al “ K” Type Thermocouple provided,
one at the bottom & one at the top .
 Heating Element : Nichrome Strip Type Heating Element provided.
 Air Circulation System : Provided 1 No. 3 HP Air circulating
system consist of SS310 fans Dia 50 mm fan shaft , bearing
for better air circulating and uniformity inside the furnace.

B. INDUCTION HARDENING MACHINE :

Induction heating is a non contact heating process which


uses the principle of electromagnetic induction to produce heat
inside the surface layer of a work-piece. By placing
a conductive material into a strong alternating magnetic field,
electric current can be made to flow in the material thereby creating
heat due to the I2R losses in the material. In magnetic materials,
further heat is generated below the curie point due
to hysteresis losses. The current generated flows predominantly in
the surface layer, the depth of this layer being dictated by the
frequency of the alternating field, the surface power density,
the permeability of the material, the heat time and the diameter of
the bar or material thickness. By quenching this heated layer in
water, oil, or a polymer based quench, the surface layer is altered
to form a martensitic structure which is harder than the base metal.
A widely used process for the surface hardening of steel. The
components are heated by means of an alternating magnetic field
to a temperature within or above the transformation range followed
by immediate quenching. The core of the component remains
unaffected by the treatment and its physical properties are those of
the bar from which it was machined, whilst the hardness of the
case can be within the range 37/58 HRC. Carbon and alloy steels

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with an equivalent carbon content in the range 0.40/0.45% are


most suitable for this process.
 Power Rating : 75 Kw ,
 IGBT Base PLC controlled scanner
 Range : ø25mm to ø90mm

F-2.03: Induction Hardening

 TESTING EQUIPMENT’S

A. RAB type Hardness Testers :

The Vickers hardness test is a versatile hardness test


method, used for both macro and micro hardness testing. It has a
broad load range, and is suitable for a wide range of applications .

The Vickers hardness test is often regarded as easier to use than


other hardness tests: The process can be performed on a
universal or micro hardness tester; the required calculations are
independent of the size of the indenter; and the same indenter (a
pyramidal diamond) can be used for all materials, irrespective of
hardness.

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F-2.04:Rockwell hardness tester

B. Micro Vickers Hardness Testing Machine :

F-2.05: Vickers Hardness Tester

C. Surface Roughness Testing Machine :

Roughness is an important parameter when trying to find out


whether a surface is suitable for a certain purpose. Rough surfaces
often wear out more quickly than smoother surfaces. Rougher surfaces
are normally more vulnerable to corrosion and cracks, but they can also
aid in adhesion. A roughness tester is used to quickly and accurately
determine the surface texture or surface roughness of a material. A
roughness tester shows the measured roughness depth (Rz) as well as
the mean roughness value (Ra) in micrometers or microns (µm).
Measuring the roughness of a surface involves applying a roughness
filter. Different international standards and surface texture or surface

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finish specifications recommend the use of different roughness filters.


For example, a Gaussian filter often is recommended in ISO standards.

F-2.06:Surface Roughness Tester

D. Metallurgical Microscope :
Metallurgical microscopes are used for metallurgical inspection,
including metals, ceramics, and other materials. A microscope is an
instrument capable of producing a magnified image of a small object. The
most common configurations of metallurgical microscopes are student,
bench top, and research.

Metallurgical Microscope
50x – 1000x Magnification with 5MP Camera

F-2.07: Metallurgical Microscope

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 INDUCTION HARDENING PROCESS FOR GEAR

Transmission component include


1) Gear & Sprocket
2) Connecting Rod
3) shaft
these component are
available in every transmission
system. Failure of any
component cause vehicle fail.
Most common failure caused due
to crack propagation So therefore
F-2.08:Failure of gear due to crack propagation
there is need to strengthen the
transmission component and its
is done via heat treatment
process.

Packaging

F-2.09:Flow chart for gear manufacturing

Induction hardening is a process where steel is hardened by


means of heating and subsequent in water.

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When the metallic work piece


(usually steel) is placed in a coil
and current is flown In the coil
then current is induced on the
surface of the metallic work piece
and it is heated up to above its
critical temperature.

TYPICAL HEAT TREATMENT PROCEDURES

 An induction heater consists


of an electromagnet - Creates
a high frequency Alternating
Current (AC).
 Heats the component(0.3%-
0.7% of carbon content) to
the Austenitizing temperature.
 Holds it at temperature long
enough to complete the
formation of Austenite

QUENCHING STAGE OF HEAT CYCLE

 Rapidly cools the metal until


Martensitic transformation
occurs.
 Changes structure from FCC
to BCC.
 Causes a transformation of
the initial structure of the steel
into Martensite.

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 PLANT LAYOUT OF HEAT TREAT WELL

F-2.10:Plant Layout of heat treat well

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 CONCLUSION

 We conclude that, while going through the entire industrial visit,


the co-operation is found to be very well organized, developed
& most ideal industry in every walk of its production,
administration & management aspects.
 We extend our heartiest thanks to Heat Treat Well, MIDC,
Nagpur for making 30th July 2018 a day to cherish for some of
the lucky students like us who are honored with your humble
gesture to get an opportunity to visit such an esteemed
organization.
 We also want to thank to director Mr. Vishram Jamdar Sir of
Heat Treat Well and to Faculty coordinator Prof. S. S. Akant
Sir, Prof. Ms. D. N. Kashyap Ma’am for coordinating the visit.

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 VISIT PHOTOGRAPH’S

P-1 Industrial Visit

P-2 Industrial visit

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CHAPTER: 3

 REFERENCES

 https://kineticgears.in
 https://www.indiamart.com/kinetic-gears/
 https://www.tradeindia.com/Seller-254310-KINETIC-
GEARS/
 https://www.justdial.com/Nagpur/Kinetic-Gears-Midc-
Industrial-Area-MIDC/0712P7104-7104-091120210651-
V9Z9_BZDET
 https://www.google.co.in/search?q=Kinetic+gear+nagpur&so
urce=lnms&tbm=isch&sa=X&ved=0ahUKEwi3n7fcgNndAhV
GfH0KHTz1D0QQ_AUIDigB&biw=1242&bih=602#imgrc=pR
MgHSmNZQfIhM:
 https://www.google.co.in/search?q=Kinetic+gear+nagpur&so
urce=lnms&tbm=isch&sa=X&ved=0ahUKEwi3n7fcgNndAhV
GfH0KHTz1D0QQ_AUIDigB&biw=1242&bih=602#imgrc=8-
sNYS28u3VpQM:
 https://www.google.co.in/search?q=Kinetic+gear+nagpur&so
urce=lnms&tbm=isch&sa=X&ved=0ahUKEwi3n7fcgNndAhV
GfH0KHTz1D0QQ_AUIDigB&biw=1242&bih=602#imgrc=Yb
IAQcT1DoaqgM:

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