ALD Vacuum Carburizing and Low Pressure Carburizing | LPC
FJM Cylinders Pvt. Ltd.
1. S u b m i t t e d T o
D r. R . K . G a r g
D r. P a r d e e p K u ma r
Presentation
on
6 weeks summer internship
S u b m i t t e d B y
S a h i l G a r g
1 2 0 0 1 0 0 4 0 5 5
M E F i n a l Y r.
3. About Company
The major duo of automotive parts manufacturing in India, JBM Group and N.K. Minda Group joined
hands for a joint venture with Faber Industry of Italy to manufacture high pressure gas cylinders. Faber
are the world's premier name in the field of CNG cylinders manufacturing with a comprehensive range of
cutting - end technology available around the world. The Promoters in India have a very sizeable
Engineering and R & D force and believe in constant innovation of product.
The plant is having a high degree of automation with processes and layout based on Faber
technology.
JBM Group is a focused, dynamic and progressive organization that provides customers with value
added products, services and innovative solutions. The Group has a diversified portfolio to serve in the
field of automotive, engineering & design services, renewable energy and education sectors and has an
infrastructure of 35 manufacturing plants, 4 engineering & design centres across 18 locations globally.
Company‘ theme Tag
• I – INTEGRITY
• S – SAFETY
• Q - QUALITY
5. Advantages
CNG does not contain any lead, thereby eliminating fouling of spark plugs.
CNG-powered vehicles have lower maintenance costs than other hydrocarbon- fuel-powered
vehicles.
CNG fuel systems are sealed, preventing fuel losses from spills or evaporation.
Increased life of lubricating oils, as CNG does not contaminate and dilute the crankcase oil.
Being a gaseous fuel, CNG mixes easily and evenly in air.
CNG is less likely to ignite on hot surfaces, since it has a high auto-ignition temperature (540 °C),
and a narrow range (5–15 percent) of flammability.
Less pollution and more efficiency: CNG emits significantly fewer pollutants
(e.g., carbon dioxide (CO2), unburned hydrocarbons(UHC), carbon monoxide (CO), nitrogen
oxides (NOx), sulfur oxides (SOx) and PM (particulate matter) than petrol.
For example, an engine running on petrol for 100 km emits 22 kilograms of CO2, while covering
the same distance on CNG emits only 16.3 kilograms of CO2.
Carbon monoxide emissions are reduced even further.
Due to lower carbon dioxide and nitrogen oxides emissions, switching to CNG can help mitigate
greenhouse gas emissions. The ability of CNG to reduce greenhouse gas emissions over the entire
fuel lifecycle will depend on the source of the natural gas and the fuel it is replacing.
CNG-powered vehicles are considered to be safer than gasoline-powered vehicles.
6. Process Layout
Raw material
incoming
inspection
Tube Cutting
Induction
Heating and
Bottom
Spinning
Bottom Milling
Hardness Test Heat Treatment
Neck Cutting
and Drilling
Induction
Heating and
Neck Spinning
Neck Machining
and Inspection
Hydrostatic
Stretch Test
Air Leakage
Steam Cleaning
and Air Drying
Internal Shot
Blasting
External shot
Blasting
Ultrasonic Test Data Stamping
Primer and
Painting
Valve Assembly
Frame Assembly
PDI
7. Tube Cutting
The process of cutting the required cylinder tube
lengths from the chunks of 150- 200 meters.
Cylinder Size Water Capacity
Cut tube length
L +3/-0
Squareness
‗’S’ max.
232×5 TPCO 50 1540 2.4
267×5.7 TPCO 30 837 2.7
267×5.7 TENARIS 35 937 2.7
316×6.7 TENARIS 60 1097 3.2
316×6.7 TPCO 60 1110 3.2
316×6.7 TPCO 65 1180 3.2
356×7.6 TPCO 65 995 3.6
406×8.6 TPCO 180 1857 4.1
8. S
L
To check the lengths of the tube within the range – Mostly OK
To check the Squareness value of the tubes with setsquare – Always OK
Parameters –
Ø Cutting Feed Scale (rev/min.) = 2 - 4.5 ( used = 3)
Ø Cutting Fluid – AWS 68 (cooldage)
Ø Cutting coil – Bimetallic Bandsaw coil sized 5300×41×1.3
Ø Vice Clamping Pressure = 35 – 45 Kg/cm2
Ø Blade Tension = 40 – 45 Kg/cm2
TPCO = High-quality Cylinder Steel Pipes and seamless steel pipe
Drawing
9. Induction Heating and Bottom Spinning
Induction Heat Furnace (Heating Torch Burner)
Induction heating is the process of heating an electrically
conducting object (usually a metal) by electromagnetic induction,
through heat generated in the object by eddy currents generated
through copper tubes of Heat Exchanger.
Before spinning, tube area that had to undergo seamless bending,
its temperature is raised to recrystallization tempr so that the
process of spinning can be carried out fastly and precisely. Also
intense care is undertaken in taking the tube from heat furnace to
spinning section so that time taken is limited to 2 – 3 seconds.
Voltage –
Measured Value PV – 11870C
Supply Value SV – 13000C (while working with 316×6.7)
10. Bottom Spinning
It is the process in which the red hot tube section is grinded and bended continuously along
with the water cooling, tip removal, Metal feeding to the high speed rotating tube. It is
accompanied in stages i.e.
a. Cooling and Bending for nearly 70% of total time
b. Tip removal for 10% of time
c. Surface finish by grinder ( burner off ) for 15% of time
d. Material filling for 5% of time
Parameters –
Grinder material = D2/(H11)
Burners – O2 (2.5 bar) + LPG (0.5 bar)
Spinning Temperature – 10500C
Cutting Torch – DA (acetylene + O2)
Cooling water hose inlet pressure = 3 – 4 bar
Ejector air pressure = 5 – 6 bar
Clamping Pressure = 40 – 50 bar
Material Filling ≈ 15mm
12. Induction Heating and Neck Spinning
The grinder used in the neck spinning is two stage grinder coalesced with the
resin bonded material with the bending roll somewhat roughly finished than
the neck forming roll thereby getting somewhat extra portion behind the neck
for the accuracy purpose.
13. To check For 316×6.7×60
Length L1 min. 35
Neck radius r 10
Neck radius R 165
D3 max. 45
D2 max. 19
D1 min. 42
Total Cylinder Length 965 - 975
14. Heat Treatment
Hardening - The use of this treatment will result in an improvement of the mechanical
properties, as well as an increase in the level of hardness, producing a tougher, more durable
item.
Quenching - Alloys may be air cooled, or cooled by quenching in oil, water, or another liquid,
depending upon the amount of alloying elements in the material and final mechanical
properties to be achieved. Hardened materials are tempered to improve their dimensional
stability and toughness.
Tempering - Tempering is the process of reheating the steel at a relatively low temperature
leading to precipitation and spheroidization of the carbides present in the microstructure.
Tempering is done to develop the required combination of hardness, strength and toughness or
to relieve the brittleness of fully hardened steels.
Polymer Concentration – Checked by Refractometer
Temperature measure - Pyrometer
Polymer used – S205. It is added in water to avoid cracking of cylinder when immersed in water
after hardening. It gets burned when comes in contact of cylinders. So, its concentration needs
to be checked time to time.
15. Pressure Cyclic Test
Two random cylinders, after the Heat Treatment of
the batch are selected for this test and pressure
cycled between, a upper pressure of 334 bar and
a lower pressure of 30 bar for 12,000 cycles. The
rate of pressurization should not exceed 15 cycles
per minute. Shell temperature of the cylinder
during the test is measured and recorded and it
should not exceed 50°C. Cylinder should not leak
up to the completion of 12,000 pressure cycles.
16. Setup
Br. 8 Br. 6 Br. 4 Br. 3
Quenching
Br. 6 Br. 5 Br. 2 Br. 1
Br. 7 Br. 5 Br. 2 Br.1 Br. 8 Br. 7 Br. 4 Br. 3
Zone 3 Zone 2 Zone 1 Zone 2 Zone 1
Tempering Hardening
To check for E316×6.7×60
Hardening Furnace
Tempr
(+0 / -10 )oC
Zone 1
890
Zone 2 895
Polymer Concentration (%)
9 – 11
Quenchant Tempr (oC)
50
Tempering Furnace
Tempr
(+/- 5)oC
Zone 1
580
Zone 2 580
Zone 3 580
Quenching Time (sec.)
120
Cycle Time
200
17. Hardness Test
After tempering, we check for the hardness of the cylinder to ensure for
the desired mechanical properties. Hardness is a characteristic of a
material, not a fundamental physical property. It is defined as the
resistance to indentation, and it is determined by measuring the
permanent depth of the indentation. More simply put, when using a
fixed force (load) and a given indenter, the smaller the indentation, the
harder the material.
BHN is designated by the most commonly used test standards (ASTM
E10-14nd ISO 6506–1:2005) as HBW (H from hardness, B from brinell
and W from the material of the indenter, tungsten (wolfram) carbide).
In former standards HB or HBS were used to refer to measurements
made with steel indenters.
18. HBW is calculated in both standards using the SI units as
Where:
F = applied force (N)
D = diameter of indenter (mm)
d = diameter of indentation (mm)
19. Specifications –
Ø Ball material – SS
Ø Ball diameter – 5mm, 10mm
Ø Load – 750Kg, 3000Kg
To check for E316×6.7×60
Tempered Cylinder Hardness Range 280 – 330 HBW
Indentation diameter (d) 1.815 – 1.680 mm
20. Neck Machining and Inspection
To check for C406×8.6
Plug Gauges
25.4 mm 14 full form
25.4 mm 14 effective form
To check min. Ø at small end
To check min. Ø at large end
Water Capacity 180
Cylinder Length 1652-1664
Machined Neck diameter (D) 42-44
Thread Size IS 3224
Taper Thread Plug Gauge
Plain Plug Gauge
21.
22. Water Capacity Measurement and Hydrostatic
Stretch Test
Hydrostatic Stretch test means subjecting the
cylinder to a hydrostatic pressure equal to the test
pressure of the cylinder and recording the
permanent stretch undergone by the cylinder.
Hydrostatic Testing is a non-destructive test
procedure used to check cylinders for leaks,
structural flaws, durability, and corrosion. It is used
to check a cylinder‘s structural integrity.
Check Sheet
Cylinder Size Ø316×6.7
Nominal Water Capacity 60L
Acceptable Water Capacity Range 58.5 – 61.5 L
Test Pressure 334 bar
Test pressure hold time 30 sec.
Total Volumetric Expansion (ml) At actual
Permanent expansion Not more than 10% of total
expansion
Leakage No leakage, visible bulge or
deformation
Reduction in Pressure No reduction in pressure when
cylinder is
under test
System Pressure 150 bar min.
Air Pressure 6 bar min.
23. Air Leakage Test
Air Leakage Test – This is carried out to check for the leakage (if
any) in the cylinder surface through gas filling.
This test is carried by dipping the cylinders in the water bath
(6 at a time).
Before this the necks are tight fitted with the gas pipe valves.
Then the supply of pressurized nitrogen is started at 200 bar.
Cylinders attain weight and starts submerging in the water.
Then manual detection of air bubbles or fuss noise is noticed
then there is a leakage in the cylinder.
After attaining the level of 350 bar the gas supply is turned
off.
Wait till the pressure drops to zero. Then relieve the pipe
fittings and the cylinders are moved to the steam cleaning
section one by one.
24. Steam Cleaning Test
After the air leakage test, the cylinders are delivered to the steam cleaning section. In
this section there is rig available of two cylinders at a time.
Firstly, the cylinders are held tight from the neck portion in the base plate (attached
to the platform) via pneumatic operated holders.
Then the platform is lifted up to the straight vertical position so that the mouth of
the cylinder is bottom facing
The pipe with the valve attachment is fastened into the neck.
Then the steam supply at test pressure of 155 Kg/cm2 is turned ON. There is
provided some clearance provided between neck and attachment so that steam and
water can discharge out after condensing.
This testing goes for nearly 15 minutes when the discharge starts coming out in the
form of steam only.
Then the steam supply is turned off and attachment is removed. Also a stick is used
to remove the chips (if any) formed during the neck threading process in the vertical
position only by revolving the stick (slight bend at the end).
After this the platform is brought to the initial position, cylinders are released from
holders and moved back via conveyor.
25. Air Drying Test
This is basically the drying of the cylinder in the atmospheric
air. As the cylinder have passed through steam testing the
temperature of the cylinder goes up and with the heat
rejection the cylinder is kept for nearly 12-14 minutes for
drying in the storage section from where it is transferred via
conveyor to the internal shot blasting.
Precautions –
Proper drying is necessary otherwise during the shot
blasting the shots will stuck to the internal surface and will
ultimately deter the quality.
Gloves are compulsory while handling the steam cleaning
test as the temperatures of the cylinder rises to 110-150oC.
26. Internal and External Shot Blasting
Internal Shot Blasting – This process consists of improving
the surface finish of the internal surfaces with the help of
blasting the internal surface with the minute steel balls with
the help of high speed rotating nozzle with two mouth
opening. The nozzle is carried in the steel lance. The complete
chamber is closed during the process.
External Shot Blasting – In this set up the multiple nozzles are
incorporated in the horizontal chamber. The specifications
remain the same except the ball size which is 1mm at this
time. It is done just after internal shot blasting but on
different setup. A rubber cap is tightened to the neck to
prevent the damaging of the threads. Before this it is ensured
that there are no steel balls left in the cylinder after the
internal shot blasting via check through bulb rod
27. Components need to be checked periodically
during the blasting are –
a) Dust Collector – In this tank the steel balls after
use are dumped in so that they can be re used. And
also the fresh steel balls are fed in this tank only for
the regular supply to the machine
b) Leather pipe – The left out long chips are carried
by this pipe from the cylinder.
So it needs check time to time for the proper working
c) Suction Pipe – The desired air pressure is
supplied via suction pipe from air tank to the nozzle.
So, before starting the power supply of the nozzle,
this air pressure build up is turned ON.
Steel balls Ø0.8 mm S330
Steel Lance Ø16.5×3×4000
Air pressure 5.5-6.5 Kg/cm2
Target 16cyl/hr.
Time Required
1min. – Loading
4min. – Process
1min. - Unloading
28. Data Stamping
The data stamping machine is universal i.e all three
direction stamping is performed
X – Stamping Slide
Y – Lateral Slide
Z – Angular Slide
X
Y
Z
29. Testing
a) Material Test
b) Tensile Test
c) Bend Test
d) Impact Test
e) SSCR Test
The sample for test(s) a,b and c above are selected by BIS and
PESO Faridabad during the manufacture of Prototype and the tests
are conducted in house in the presence of BIS and PESO.
The sample for test ‘d’ above are selected by BIS and PESO and the
sealed sample is send to third party lab approved by BIS for testing.
The test results are directly send to BIS by the lab.
30. Stamp
A A U B 0 4 6 F J M C M / L
9 9 9 6 6 2 9 0 6 / 2 0 1 5 I S 1 5 4 9 0
T P 3 3 4 B A R A A U B 0 4 6
T W 6 0 . 6 K G W C 6 0 . 0 L W P 2 0 0 B A R O N B C N G
DO NOT USE AFTER 06/2035
Meanings –
AAUB – Batch code
046 – Cylinder No. FJM – Company name
CM/L 9996629 – company manufacturing license no.
06/2015 – month and year of manufacture
IS 15490 – Indian Standards
TP – Test Pressure
TW – Tear weight
WC – Water Capacity
ONB – On Board
31. Primer Painting
Primer Coating Thickness 40 µm ( min.)
Painting Defects
There should not be any over flow,
dust,
orange peel and blisters
Oven Temperature 800C +/- 100C
Baking Time 20 – 25 mins.
Bottom Gun air pressure 6 Kg/cm2 (min.)
Reciprocator air pressure 1.5 – 2.5 Kg/cm2 (min.)
Time 20 – 30 sec.
Thinner 20% of total volume
Primer and Hardener mixing ratio 4:1
32. Finish Painting
Primer + Paint Coating Thickness 80 µm ( min.)
Painting Defects
There should not be any over flow, dust,
orange peel and blisters
Oven Temperature 800C +/- 100C
Baking Time 40 – 45 mins.
Bottom Gun air pressure 6 Kg/cm2 (min.)
Reciprocator air pressure 1.5 – 2.5 Kg/cm2 (min.)
Time 20 – 30 sec.
Thinner 20% of total volume
Paint and Hardener mixing ratio 3:1
Salt Spray Test There should not be any red rust in 500 hrs.
33. Valve Assembly
Procedure –
Affix the cylinder neck to the base plate.
Make sure that the glue tape be winded on the valve accurately so that there will not
be any problem in tightening the valve to the cylinder
Scan the QR code of the valve for the system entry. Start only after getting green
signal from the setup.
Firstly take the valve, place it to the neck slightly, put the face plate over the valve
then hold the gun with hand, place it onto the face plate and hold the button.
Release the button when the setup indicates red light.
Then place the gun apart and the valve is checked for torque via Torque Wrench
manually for the perfection.
Precaution –
The acceptable torque is within +/- 10 ranges. If it is over tightened then
valve is damaged and if it is somewhat less tightened then there is danger of leakage.
So, a skilled operator is assigned this task usually.
Cylinder Size Ø316×6.7 mm
Water Capacity 60 L
Torque 270 Nm
34. Frame Assembly
The measuring of the Tare weight of cylinder after de-gassing.
Then lifting it up and putting on the fixture for frame assembling.
Using pneumatic adjuster cylinder is adjusted as per the markings
on the fixture.
Then frame is tightened on the cylinder. It consists of three straps
and one bottom
The bolts are tightened to the strap to strap and the strap to frame.
It is divided into two parts –
Initial bolt tightening will take place after two hours of de-gassing
Final bolt tightening and checking will take place after two hours of
initial bolt tightening
The finally the stickers of CNG and Precaution are pasted on the
cylinder.
