Friction welding

1. CP 302 Presentation
Presented By : Yashwant Goma
: Aditya Rajak

2. Simulation of friction welding using FEM model

3. Production Department
The production department is divided in
1. Mixing zone.
2. Extrusion zone.
3. Dye shaping zone.
4. Calibrating zone.
5. Calendaring zone.
6. Haul off zone.
7. Cutting zone.

4. The mixing zone of the department is the first place
where the powdered poly vinyl chloride is put in to the
mixer machine where it is blended at a high
temperature of 110 degree Celsius in a container of
capacity 5 tons. The raw material is fed in to feed
hopper which is conical in shape and it guides the raw
material to fit in to the mixing machine without
blockage and uniformly.
Mixing Zone

5. EXTRUSION PROCESS
The extrusion process is the process in which a solid powdered
material is converted into the semi liquid form and then to the desired
form with the help of dies fitted at the end. The conversion is done
with gradual heating of raw material in the barrel with the help of
electric heater divided in different zones. The raw material is moved
forward with the help of the twin screws moving in opposite directions
at low R.P.M. it is controlled by a gearbox.
SHAPING BY DYE
The conversion of the extruded P.V.C to a furnished sheet is done
with the help of a heating dye. The purpose of the dye is to give a
perfect sheet shape to the extruded raw material. It is fixed
between the extruder and the calendar. The dye is fixed with
total of 16 thermal heaters which gives is the exact temperature
for the conversion of the raw material. The temperature is
maintained with the help of an automatic monitoring unit. oil is
circulated in to the die via two connecting pumps for outlet and
inlet to reduce the friction wear. There are two lead
thermocouples.

6. CALIBRATING ZONE
A vacuum operated calibrator is a mechanical device
which is positioned between the extrusion machine and
the calendering machine. The calibrators are vacuum
operated. The process of injection molding has to deal
with hundreds of variable. Variable can include moisture
content of the material or the temperature of the melt.
To make parts identical requires a way to guarantee that
the process variables are controlled so that they can be
held in a stable and reasonable tolerance
CALENDERING PROCESS
Calendaring is a finishing process used on
cloth, paper, or plastic film. A calendar is
employed usually to smooth, coat or reduce
the thickness of the material.

7. HAUL OFF MACHINE
The haul off rollers is mounted right after the calendar
zone. It can be integrated in the calendaring frame; it is
mounted after the conveyer In the case of thermoforming
in the line production, or can be independent. In case of
sheets for bobbin or plate production Longitudinal cutting
device for side edge trimming with winding system for
trimmed edges. This also helps the sheets to be aligned CUTTING ZONE
A trolley cutter is a device which is used to cut
the sheets in to the required dimensions. The
cutter in mounted beneath the sheets on the
fame of the calendering machine layout right
after the haul off machine. The cutter is
mounted on a trolley which is fixed to the floor.
The machine gets to and fro the rails with the
help of a chain drive

8. Embossing Process
The p.v.c sheets that are produced in the
industry are of variable textures. Most of
the sheets produced are of plain surfaces
but there are some sheets which are
given pattern to meet with needs the
customer therefore, the plant has a
different section for the production of
pattern sheets with the help of
embossing process

9. AIR COMPRESSOR SECTION
TECHNICAL COMPONENTS:
1. Motor
2. Air compressor pulley
3. Air cooler
4. Pressure switch
5. Air filter
6. Storage tank
7. Safety valve
8. Compression engine
General maintenance:
1. De- moisturization of the tank
2. Oil change.
3. Air leakage check.
4. Belt change b-91
5. Motor fixing.
6. Compressor engine maintenance.