MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight:

Slides:

Advertisements

Similar presentations

Chapter 12 Processes.

Advertisements

Ken YoussefiMechanical Engineering Dept., SJSU 1 Fundamentals of Casting Casting, one of the oldest manufacturing processes, dates back to 4000 B.C. when.

The Sand Casting Process The most commonly used Casting Process, in the entire Casting Industry. Concept: The top and the bottom of the mold form the flask.

IE 337: Materials & Manufacturing Processes

Casting By: Jackie Ho. Casting  The process of which a material is introduced into a mold in liquid state, and is allowed to solidify inside the mold,

INTRODUCTION PUMP INTRODUCTION CASTING INTRODUCTION : R K foundry works (p) limited : Its Established in year 1970 at Jaipur, Rajasthan India. R.K.

Types of Pattern Pattern Allowances

NETANYA PLASMATEC LTD Confidential 1 Plasma Casting treatment (PTC) for Ductile Iron.

© Prof. B. Ravi, I.I.T. Bombay Project Name E-Foundry Project Student Name: Degree, Year: Branch: Institute: Student Name: Degree, Year: Branch: Institute:

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN © 2006 Pearson Education, Inc.,

Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 10-1 CHAPTER 10 Fundamentals of Metal-Casting.

Die Casting Basics Die is closed. Metal is drawn in to tool (plunger). Tool injects metal into cavity. Cavity continues to fill. (fractions of a second)

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e Classification of solidification processes.

Optimization of Casting Process Design with SOLIDCast® and HyperOpt®

Types of Pattern and their Material, Pattern Allowances

Permanent Mould Casting

Manufacturing Processes

Casting Workshop Technology

IE 337: Materials & Manufacturing Processes

MT-284 MANUFACTURING PROCESSES INSTRUCTOR: SHAMRAIZ AHMAD MS-Design and Manufacturing Engineering Topic: Casting Defects and Mold.

Moulding Materials and their Characteristics

ME 3351 Manufacturing Processes Tutorial 3 Eng. Ahmad Aljazea.

FUNDAMENTALS OF METAL CASTING

1Module 4b Casting process (continued). Module 4a2 Casting Principle of the process Structure Process modeling Defects/quality control Design and DFM.

Casting Mukul Gupta ID# M-L. Casting A manufacturing process used to solidify objects from their liquid form into various useful shapes by introducing.

METAL CASTING PROCESSES 1.Permanent Mold Casting Processes ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e.

Chapter 13: Multiple-Use-Mold Casting Processes

Tutorial: Engineering technology Topic: Castings defects Prepared by: Ing. Elena Nová Projekt Anglicky v odborných předmětech, CZ.1.07/1.3.09/

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION PROJECT NAME: CHARGE AIR PIPE.

Chapter 13 Multiple-Use-Mold Casting Processes (Part I) EIN 3390 Manufacturing Processes Summer A, 2012.

DESIGN CONSIDERATIONS CAREFUL CONTROL OF LARGE NUMBER OF VARIABLES NEEDED- CHARACTERISTICS OF METALS & ALLOYS CAST METHOD OF CASTING MOULD AND DIE MATERIALS.

1 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D NEW PRODUCT DEVELOPMENT NEW PRODUCT DEVELOPMENT By V.Neville Gnanaraj.

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d PRODUCTIVITY IMPROVEMENT PRESENT METHOD Component Name: U- Bolt Component weight:

ENERGY IS____________________________________________. WORK CANNOT OCCUR________________________________! THERMAL ENERGY ) THERMAL.

Metal Casting By Tanner Powell. Overview of Casting  Net or near net  One of the most utilized production methods  Many different types of casting.

Fundamentals of Metal Casting

CASTING DEFECTS AND INSPECTION. The defects in a casting may be due to pattern and moulding box equipment, moulding sand, cores,gating system or molten.

MANUFACTURING PROCESS Prof. Kiran Gore Unit -3. What is ‘Manufacturing’?  Process of converting raw material in to finished goods, with the combination.

Art in Action 2010 Artist James Lynxwiler. The artist set up his studio in Old Town Square starting with a welded metal armature.

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d PROBLEM SOLVING OLD METHOD Component Name: Gear Stay Component weight: 182Kgs Number.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN © 2006 Pearson Education, Inc.,

Casting & Welding Engineering (IE 203) Second Year, Industrial Engineering Dept., Faculty of Engineering, Fayoum University Dr. Ahmed Salah Abou Taleb.

Finding the Density for layers.  Check out this picture from your book. Which layer has the highest density?  Which layer has the lowest density? 

Casting process.

The relationship between temperature and volume. If we place a balloon in liquid nitrogen it shrinks: How Volume Varies With Temperature So, gases shrink.

Kalpakjian Schmid Manufacturing Engineering and Technology © 2001 Prentice-Hall Page 12-1 CHAPTER 12 Metal Casting: Design, Materials, and Economics.

Foundry Sands Silica (SiO 2 ) or silica mixed with other minerals Good refractory properties ‑ capacity to endure high temperatures Small grain size yields.

1Module 4b Casting process (continued). Module 4a2 Casting Principle of the process Structure Process modeling Defects/quality control Design and DFM.

 IN VERTICAL CENTRIFUGAL CASTING PROCESS  A PERMANENT MOLD IS ROTATED ABOUT ITS VERTICAL AXIS  THE MOLD IS SPUN AT HIGH SPEEDS ( USUALLY 50 TO 100.

GROUND SERVICING OF VARIOUS SUB SYSTEMS

Quality Control Done By: Mohammed al sadah –

Metal Casting - by MANIGANDAN.

PATTERN MATERIAL REQUIREMENTS OF A GOOD PATTERN MATERIAL: IT SHOULD BE

Technical University of Denmark

Pattern Allowance in Casting

Classification of solidification processes

NET SHAPE PROCESS SUBMITTED BY: TRUPTI RANJAN BISWAL

Solid Solution Thermal Equilibrium Diagram

kyle brown, danavi wollin

Part II Metal-Casting Processes and Equipment

Casting Design Modifications

Solidification Time Whether the casting is pure metal or alloy, solidification takes time. The total solidification time is the time required for the casting.

Sand casting. Steps: 1.Mechanical Drawing of the part

Weighted Interval Scheduling

Casting process.

THE PROCESS FOR REPORTING ABNORMALITIES

Casting process (continued)

FIRST TIME RIGHT Component Name : Adapter Component weight : 18.2Kgs

Weighted Interval Scheduling

D × t % A Wt. of liquid Wt. of water × dwd =.

Presentation transcript:

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d REJECTION REDUCTION OLD METHOD Component Name: Bearing Housing Component weight: 20Kgs Number of Castings per Mold: 1nos. Total Good Casting wt : 20Kgs Total Pouring wt : 30.5kgs Yield : 65.5% REJECTION DESCRIPTION Component getting rejected at customer end after machining due to shrinkage problem

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Hotspot inside the Casting & Feeder Hotspot specifies the isolated regions and solidification time Hotspot inside the casting

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows the possible Shrinkage area Shrinkage location This defect location exactly matches with customer complaint

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Corrective Action Process changed to Furan Fast Loop Line from High Pressure Molding line Feeder position and neck size corrected. Number of Castings per Mold increased to 2 from 1 REJECTION REDUCTION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Metal Filling at various intervals The colour scale shows the temperature at each location

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Picture shows Hotspot inside the Casting & Feeder Hotspot specifies the isolated regions and solidification time

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Finding after implementation of this method 1.Hotspot moved to feeder and there is no defect noticed inside the casting. 2.Yield also increased by 7%