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Final presentation for ip 2
1. QUALITY INSPECTION
COUPLINGS , BLADE & ROTOR
INDIA
Presented By
Sangram Singh Verma
Intern
Guided By
Yallala Sudhakar
Quality Rexnord- International
Presented To
Quality & Team
Guided By
Dr. A.Chandrashekhar
Chairperson - Students Welfare
2. The internship opportunity I had with Rexnord Euroflex India
Private Limited was a great chance for learning and professional
development. Therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be a part of it. I
am also grateful for having a chance to meet so many wonderful
people and professionals who lead me though this internship
period.
Acknowledgement
3. Rexnord Corporation is a Milwaukee, Wisconsin-based company
listed on the New York Stock Exchange (NYSE: RXN). It was
founded in 1891 by Christopher Levelly and incorporated in 1892
as the Chain Belt Company. It had "$67.5 million in profit and $1.9
billion in sales" in 2016.
Rexnord was founded as the Chain Belt Company by inventor
Christopher W. Levelly at the age of 58.
About Company
4. Levelly, along with Chain Belt co-founders F.W. Sivyer and W.A.
Draves, held the first board of directors meeting on September 9,
1891. Chain Belt was incorporated in the state of Wisconsin on
February 24, 1892.
In 2016, Rexnord opened its new Water Management platform
headquarters in Milwaukee. Euroflex Transmissions (India) Private
Limited, a Joint Venture Company formed in 1991 with Euroflex
Transmissions Limited of the U.K., is in the business of the design
and manufacture of the High Performance Flexible Disc Couplings
for applications in Gas Turbines, Industrial Steam Turbines,
Centrifugal Compressors, Large Pumps, Blowers, etc.
5. The Couplings designed and manufactured by Euroflex (India),
are being exported to various parts of the World including
Japan, Germany, France, U.K. Switzerland, The Netherlands,
Sweden etc. apart from meeting the requirements in India.
The Euroflex designs have been found to be on par with the
best and at times, even better than the rest in the field of
Flexible Disc Couplings.
6. Raw Material Categorization (Bars)
1. According Diameter
2. According Material
3. According Heat Treatment
According Diameter
In this specification bars can be categorized according
based on their diameter.
According Material
Here bars are specified according material by what
they made of, example
EN-8 EN-19 EN-24 EN-26
7. According Heat Treatment
In this category BARS are specified according
Heat treatment (HEAT CONDITION)
Example
T-CONDITION V-CONDITION W-CONDITION X-CONDITION Y-CONDITION
BLUE WHITE RED GREEN YELLOW
Heat Treated/ Without Heat Treatment Without Heat Treatment
10mm to 125mm 130mm to 400mm
8. Raw Material for Blade (BILLET)
Billet is casted material in shape of square/rectangle cross section
by hot work rolling and extrusion as raw material. Billets are
relatively larger than bars.
Material: X22
Use: Raw material for Turbine blades
Dimensions
Element Fe Cr Ni Mo Mn Al
% 83.5-87 11.0-12.5 0.30- 0.80 .8-1.20 .40-.90 .20-.80
Cross section 120*120 65*50 100*40 100*90 100*80
Length: It varies 4 meter to 5 meter
9. Non-metallic inclusions are chemical compounds and non-metals that are
present in steel and alloys.
They are the product of chemical reactions, physical effects, and
contamination that occurs during the melting and pouring process.
These inclusions are categorized by origin as either endogenous or
exogenous. Endogenous inclusions, also known as indigenous, occur within
the metal and are the result of chemical reactions. These products precipitate
during cooling and are typically very small. Exogenous inclusions are caused
by the entrapment of non-metals. Their size varies greatly and their source
can include slag dross flux residues, and pieces of the mould.
Sulphur : FeS, MnS, Al2S3, CaS, MgS, Zr2S3
Nitrogen: ZrN, TiN, AlN, CeN
Oxide: FeO, MnO, Cr2O3, SiO2, Al2O3, TiO2
Note: Mainly inclusion is the Degrading factor for material properties in bar.
10. Material
Heat Treated No HT
Supplier
Certificates Certificates
Mechanical/Chemical Properties Mechanical/Chemical Properties
Inventory
Lab
Lab Report
Red FlagRed Flag
Satisfa
ctory
YES
ON
NO
Sample
Again Heat
Treatment
Material Acceptance Flow Chart
11. Non-destructive Testing (NDT)
This is the process of inspecting or evaluating materials, components or
assemblies for discontinuities, or differences in characteristics without
destroying the serviceability of the part or system. In other words, when
the inspection or test is completed the part can still be used.
Method used for Non-Destructive Testing
Magnetic Particle testing
Liquid Penetrant testing
Ultrasonic testing
Electromagnetic testing
Visual Testing
12. Ultrasonic Testing
In this method ultrasonic rays are used to test internal cracks, Blow holes
and other defects by using various range of frequency according component
size and thickness. Here a lubricant is used to make a good contact between
surface and prob.
Principle
Driven by the pulse, the transducer generates
high frequency ultrasonic energy. The sound energy is introduced and
propagates through the materials in the form of waves. When there is a
discontinuity (such as a crack) in the wave path, part of the energy will be
reflected back from the flaw surface.
13. Ultrasonic testing uses high frequency sound waves of a range between 0.5
to 15 MHz to conduct testing.
14. Magnetic particle Inspection (MPI)
This is a non-destructive testing (NDT) process for detecting surface and
shallow subsurface discontinuities in ferromagnetic materials such as iron,
nickel, cobalt, and some of their alloys. The process puts a magnetic field
into the part.
Principle
It works on principle of flux leakage.
15. Dye Penetrant Testing
This inspection also called liquid penetrate inspection or
penetrant testing (PT), is a widely applied and low-cost inspection method
used to check surface-breaking defects in all non-porous materials (metals,
plastics, or ceramics).
Principle
The principle of liquid penetrant testing is that the liquid
penetrant is drawn into the surface-breaking crack by capillary action and
excess surface penetrant is then removed; a developer (typically a dry
powder) is then applied to the surface, to draw out the penetrant in the
crack and produce a surface indication.
16.
17. HRC Testing
This machine works on principal of Rockwell and Brinell
tester, Difference is easy handling means portable.
18. Visual Inspection
It used in maintenance of facilities, mean inspection of
equipment and structures using either or all of raw human senses
such as vision, hearing, touch and smell and/or any non-
specialized inspection equipment.
19. CO-ORDINATE MEASURING MACHINE (CMM)
A coordinate measuring machine (CMM) is a device that measures the
geometry of physical objects by sensing discrete points on the surface of the
object with a probe. Various types of probes are used in CMMs, including
mechanical, optical, laser, and white light.
Principle
A coordinate measuring machine (CMM) works in much the same way as your
finger when it traces map coordinates; its three axes form the machine's
coordinate system. Instead of a finger, the CMM uses a probe
to measure points on a work piece.
20. Type of CMM
There are four basic types of coordinate measuring machines:
bridge, cantilever, gantry and horizontal arm. Each one provides
unique advantages based on the components being measured.
21. 1. Bridge-Type
Moving-bridge coordinate measuring machines embody the principle of
design now most often used in larger machines. The bridge and its uprights
or columns move along the primary (usually X) axis. A carriage moves
laterally on the bridge along the secondary (usually Y) axis.
22. 2. Cantilever-Type
The cantilever CMM machine was the initial design of Ferranti in Scotland
in the 1970s, and today they are manufactured in small numbers, usually as
shop floor hard bearing machines. Generally used for measuring relatively
small parts, they provide open access to the operator on three sides.
23. 3. Gantry-Type
The largest stationary gantry- and bridge-type 3D coordinate
measuring machines (CMMs) from Hexagon Metrology will give
you gargantuan performance. It is not just the capacity of these
giants of the world of coordinate measuring systems that leaves
all others in the shade: they also impress with robust materials, a
stable structure and high accuracy - on the production floor, in a
production cell or in the measuring room. The CMMs can act as a
standalone system or as a station in a production cell.
24.
25. 4. Horizontal Arm-Type
The advantages of the horizontal arm coordinate measuring
machines (CMMs) from Hexagon Manufacturing Intelligence are
particularly apparent when inspecting sheet metal parts in the car
industry, or other large-volume components in the aerospace,
ship, defense, appliance, machinery and railway industries. Their
open structure permits direct access to the work piece and
therefore significantly eases loading and unloading. Horizontal
CMMs can also be integrated as a component of an automated
production line such as automotive body-in-white.
26.
27. A coordinate measuring machine (CMM) is a device used in the
measurement of the physical geometrical characteristics of an
object. DCC CMMs can be programmed to repeatedly measure
identical parts; therefore this can be seen as a specialized form of
industrial robot.
28.
29.
30.
31.
32. Four Modes of Operation
Manual Mode
Teaching Mode
Interactive Mode
Programming Mode
- Manual Program
- Automatic Program
33.
34.
35.
36.
37. Compute straightness for following data captured using CMM
(10.03, 29.98)
(12.96, 39.02)
(40.05, 119.89)
(14.94, 45.1)
(50.0, 149.88)
40. Turbine Rotor
A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating output
shaft. Its modern manifestation was invented by Sir Charles Parsons in
1884.
Because the turbine generates rotary motion, it is particularly suited to
be used to drive an electrical generator—about 85% of all electricity
generation in the United States in the year 2014 was by use of steam
turbines. The steam turbine is a form of heat engine that derives much of
its improvement in thermodynamic efficiency from the use of multiple
stages in the expansion of the steam, which results in a closer approach
to the ideal reversible expansion process.
44. Inspection Gauge
For inspection of rotor grooves there are no predesigned gauges are
available in the market because size of grooves changes rotor to rotor. So
these are following steps to inspect rotor.
1. Design of Groove gauge
2. Material selection(Sheet)
3. Wire cutting / laser cutting
4. CMM Inspection of gauge
5. Rotor groove Inspection
46. 3D PRINTING
Conversion of a three-dimensional digital model in to a physical object
from typically by laying down many thin layers of a material in succession
by machine(Robot).
50. 3D PRINTING DATA
S.R No Parameter
1 Model Turbine Rotor
2 Modeling Software Solidworks
3 Material Polylactic Acid
4 Nozzle Temperature 210OC
5 Bed Temperature 45OC
6 Infill 30%
7 Nozzle Diameter 0.2mm
53. Result
As Shown in the above graph actual dimensions are less than
nominal , Because after printing material temperature decreases and it
get reduced from its nominal size, So before printing a component
synchronizing factor also should be included for perfect size.
54. Conclusion
It is well known that Quality can be assure with
the help of inspection, testing/ cross verifications. Quality is
backbone for any industry and future can be predicted on basic
of quality. Being a part of quality team work environment was
bit challenging where even five micron deviation leads toward
rework or rejection but it helped me a lot to grow my
knowledge domain about handling of Inspection Instrument.
