1. Wheels India Ltd is an auto component manufacturer that produces wheels and other parts. They were experiencing high scrap rates of around 10,000 PPM due to defects in butt welding of passenger car rims.
2. A study was conducted to analyze the defects, temperature behavior, material properties, quality verification process, and potential causes of welding failures like fusing. DOE tools like product/process search were used to validate causes.
3. It was found that variations in the initial bed gap/platen home position was a significant cause of failure, with a count of defects matching this cause being greater than the threshold of 6 out of 16 samples. Other factors like excess edge cutting were not found to be
The document summarizes the Indian steel industry. It discusses that India is the 3rd largest producer of raw steel globally. It outlines the history and establishment of major steel plants in India such as Tata Steel and Steel Authority of India Limited (SAIL). Current major steel producers in India like Tata Steel, Essar Steel, and JSW Steel are also summarized. The role of the steel industry in the Indian economy and employment opportunities are highlighted. Issues faced by the industry such as capital, technology, productivity, and shortage of raw materials are briefly mentioned.
The document discusses the steel industry in India from a global perspective. It provides statistics on India's position as the 4th largest steel producer in the world in 2011. The key growth drivers for steel demand in India are identified as infrastructure development, manufacturing sector growth, and an increasing population. While the steel industry has grown significantly, challenges remain around dependence on imported materials, low production efficiency, and inadequate infrastructure. The document examines trends in steel production, consumption, technology and raw material sources. It outlines India's potential for further industry expansion to meet rising domestic demand.
This document provides a winter training report submitted by Pranshu Prakash Tiwari to Neel Metal Products Limited in Haridwar, India. The report details Tiwari's in-plant internship focusing on different welding techniques used in manufacturing the body of the Bolero vehicle. It includes sections on safety precautions, an overview of the company, different types of welding processes like MIG and spot welding, the production process for making Bolero bodies, and tools used. The report evaluates welding techniques employed at JBM, specifically examining MIG welding and spot welding.
Gravity die casting involves melting an alloy of zinc and aluminum and pouring it into an open steel mold. The mold is then turned upside down and tapped to release the finished casting. Common items made through gravity die casting include toasters, lawnmowers, and car wheel rims.
Tanishq ‘s New Destination Stores Strategy.ppt final 1Sourav De
Tanishq is India's largest jewelry retailer with over 40% market share in the branded jewelry segment. It has 117 stores across 70 cities, primarily located in high street areas. Last year, Tanishq had over 1.5 million customers. The company aims to expand its retail footprint and launch specialized regional collections to cater to brides from different communities. Tanishq plans to open 17 more boutiques in 2010, focusing on large format stores over 4,000 square feet to maximize its brand presence.
Metals are generally found as compounds in nature called minerals. Ores are minerals that metals can be extracted from readily and profitably. Ores occur as oxides, sulfides, carbonates, sulfates, chlorides, and silicates. Flux is added to slag off impurities during smelting. Metals are refined through vapor phase, electrolytic, or zone refining. Common metal extraction processes involve concentration, roasting, smelting, and reduction. Metals have various uses as alloys and in electroplating, machinery, jewelry, and other applications.
Metallurgy based on chemistry the reactions and processesJustin George
This document discusses metallurgy and metal extraction processes. It covers key topics such as mineral ores, concentration methods like froth flotation and magnetic separation, production of crude metal through processes like smelting and calcination, and refining of crude metal using techniques including liquation, distillation, and electrorefining. Specific extraction processes are described for metals like aluminum, copper, iron, and zinc. Thermodynamic principles and the use of Ellingham diagrams to determine the feasibility of thermal reduction reactions are also summarized.
The document summarizes the Indian steel industry. It discusses that India is the 3rd largest producer of raw steel globally. It outlines the history and establishment of major steel plants in India such as Tata Steel and Steel Authority of India Limited (SAIL). Current major steel producers in India like Tata Steel, Essar Steel, and JSW Steel are also summarized. The role of the steel industry in the Indian economy and employment opportunities are highlighted. Issues faced by the industry such as capital, technology, productivity, and shortage of raw materials are briefly mentioned.
The document discusses the steel industry in India from a global perspective. It provides statistics on India's position as the 4th largest steel producer in the world in 2011. The key growth drivers for steel demand in India are identified as infrastructure development, manufacturing sector growth, and an increasing population. While the steel industry has grown significantly, challenges remain around dependence on imported materials, low production efficiency, and inadequate infrastructure. The document examines trends in steel production, consumption, technology and raw material sources. It outlines India's potential for further industry expansion to meet rising domestic demand.
This document provides a winter training report submitted by Pranshu Prakash Tiwari to Neel Metal Products Limited in Haridwar, India. The report details Tiwari's in-plant internship focusing on different welding techniques used in manufacturing the body of the Bolero vehicle. It includes sections on safety precautions, an overview of the company, different types of welding processes like MIG and spot welding, the production process for making Bolero bodies, and tools used. The report evaluates welding techniques employed at JBM, specifically examining MIG welding and spot welding.
Gravity die casting involves melting an alloy of zinc and aluminum and pouring it into an open steel mold. The mold is then turned upside down and tapped to release the finished casting. Common items made through gravity die casting include toasters, lawnmowers, and car wheel rims.
Tanishq ‘s New Destination Stores Strategy.ppt final 1Sourav De
Tanishq is India's largest jewelry retailer with over 40% market share in the branded jewelry segment. It has 117 stores across 70 cities, primarily located in high street areas. Last year, Tanishq had over 1.5 million customers. The company aims to expand its retail footprint and launch specialized regional collections to cater to brides from different communities. Tanishq plans to open 17 more boutiques in 2010, focusing on large format stores over 4,000 square feet to maximize its brand presence.
Metals are generally found as compounds in nature called minerals. Ores are minerals that metals can be extracted from readily and profitably. Ores occur as oxides, sulfides, carbonates, sulfates, chlorides, and silicates. Flux is added to slag off impurities during smelting. Metals are refined through vapor phase, electrolytic, or zone refining. Common metal extraction processes involve concentration, roasting, smelting, and reduction. Metals have various uses as alloys and in electroplating, machinery, jewelry, and other applications.
Metallurgy based on chemistry the reactions and processesJustin George
This document discusses metallurgy and metal extraction processes. It covers key topics such as mineral ores, concentration methods like froth flotation and magnetic separation, production of crude metal through processes like smelting and calcination, and refining of crude metal using techniques including liquation, distillation, and electrorefining. Specific extraction processes are described for metals like aluminum, copper, iron, and zinc. Thermodynamic principles and the use of Ellingham diagrams to determine the feasibility of thermal reduction reactions are also summarized.
The document discusses the refining and purification process of zinc. It begins with an introduction to zinc including its chemical formula, atomic number, and color. It then discusses the history of zinc discovery and production. The main uses of zinc are then outlined, followed by global zinc production and reserve statistics. The key steps in the zinc refining and purification process are then described in detail, including roasting, leaching, purification, electrolysis, melting and casting. Gas cleaning and sulfuric acid production are also summarized. Finally, the main applications of zinc in automotive, construction, hot dip galvanizing, and zinc castings are briefly outlined.
Manufacturing of Gold and Diamond Jewellery. Opportunities for Entrepreneurs to Start Own Business of Gold and Diamond Jewellery.
Jewellery or Jewellery consists of decorative things worn for personal adornment, similar to brooches, rings, necklaces, earrings, pendants, bracelets, and cufflinks. Jewellery could also be attached to the body or the clothes. From a western perspective, the term is restricted to durable ornaments, excluding flowers as an example. For many centuries metal, usually combined with gemstones, has been the normal material for Jewellery, however different materials similar to shells and other plant materials could also be used.
For More Details, Click Here: - https://bit.ly/2Zuj0LQ
Contact us
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886
Mobile: +91-9097075054, 8800733955
Website: www.entrepreneurindia.co , www.niir.org
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
The document discusses the process of making steel, including the raw materials, production processes, and applications. Key points:
- Raw materials include iron ore, limestone, coke, and scrap metal. Iron ore is purified and melted in blast furnaces with coke and limestone.
- Primary production methods are basic oxygen furnace (BOF) and electric arc furnace (EAF), which further refine molten iron into steel.
- Secondary processes like degassing and temperature control produce semi-finished and finished steel products.
- Steel products have many applications in infrastructure, vehicles, machinery, and more due to their strength and cost effectiveness.
This document provides information about nickel, including its introduction, ores, extraction, alloys, and properties. It discusses that nickel was first isolated in 1751 and belongs to the transition metals. It has an FCC crystal structure and is both hard and ductile. The document also describes some common nickel alloys like Monels, Inconel 600, and Nichrome, providing their compositions, properties, and applications.
Copper is a reddish-colored metal with many useful properties and applications. It has a density of 8930 kg/m3 and melts at 1083°C. Copper occurs naturally and is extracted via mining and smelting. It has high tensile strength, ductility, and thermal and electrical conductivity. Copper is used extensively in building construction for roofing, flashing, gutters, pipes, wiring and more due to its durability, corrosion resistance and recyclability. Common copper alloys include brass and bronze.
The steel industry in India is affected by macroeconomic factors like GDP growth and inflation. Higher GDP growth leads to increased steel consumption for infrastructure and other sectors, fueling steel industry growth. However, high inflation has negatively impacted the steel industry by slowing growth in key customer industries like automobiles and construction. Rising inflation has also reduced consumer demand for housing and vehicles. The Reserve Bank of India's interest rate hikes to combat inflation have further raised borrowing costs, negatively impacting steel-intensive industries.
Ferrous metals are metals that contain iron, such as steel which is an alloy of iron and carbon. The amount of carbon determines the properties and applications of different types of ferrous metals. Pig iron contains a high amount of carbon (2-4%) and is very hard and brittle. It is used to make steel. Cast iron also contains 2-4% carbon and is strong under compression. Wrought iron contains a very low amount of carbon and is tough and malleable. Steel contains 0.15-1.5% carbon and includes low, medium, and high carbon varieties with different properties. Alloy steels like stainless steel add other elements like chromium for improved properties such as corrosion resistance. Fer
The automobile sector is a major consumer of castings produced in India. Currently, there are around 4,500 foundry units in the small, medium and large-scale sector. Out of these, 1500 units have international quality accreditation. Read More: https://bit.ly/2T9nh71
#marketresearch #marketreserachreport #foundrymarket #business
The document discusses the chemical properties of alkali metals. It explains that alkali metals react vigorously with oxygen and water. The reactivity increases down the group as the atoms get larger, shielding the outer electrons from the nucleus and making them easier to lose. Equations for reactions of lithium, sodium, and potassium with oxygen, water, and other substances are provided. Flame tests for group 2 metals are also discussed.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
1). The document summarizes information about nickel, including its extraction from ores, properties, advantages, disadvantages, and classifications of nickel alloys. Nickel is extracted via pyrometallurgical or hydrometallurgical processes depending on the ore. 2). Important nickel alloys include nickel-copper alloys, nickel-chromium alloys, and nickel-base superalloys used in applications requiring high heat resistance. 3). Nickel has properties like corrosion resistance and is used to make alloys for applications across many industries.
Corrosion and corrosion inhibition of aluminum and aluminum alloys in acid me...mohammed rida
This document provides an introduction to aluminum, its key characteristics, aluminum alloys, corrosion of aluminum in acid solutions, and corrosion prevention methods. It discusses the low density, strength, corrosion resistance, conductivity, and other beneficial properties of aluminum. It describes common aluminum alloying elements like copper, magnesium, silicon, and their effects. The document also examines various types of localized corrosion that can affect aluminum, such as pitting, crevice, and galvanic corrosion. Finally, it outlines approaches for corrosion prevention, including alloy selection, coatings, use of inhibitors, and design considerations.
The document provides information on cast iron, including its history, manufacture, composition, types, properties, uses, production/processing, and future applications. Some key points:
- Cast iron was invented in China in the 5th century BC and has carbon content above 2%.
- It is manufactured by re-melting pig iron in a cupola furnace to remove impurities and produce molten cast iron for casting.
- The main types include grey, white, mottled, chilled, and spheroidal graphite (ductile) iron.
- It has properties of being relatively low melting, strong in compression but weak in tension, and not magnetic or ductile.
- Common uses include
IN THIS PPT U WILL LEARN ABOUT THE FOLLOWING SUB-TOPICS OF MANGANESE:-
-Uses
-Distribution
-Eco Significance
-Reserves in India
-Agencies exploring it
-Problems related to its exploitation
-Marketing and Production strategy
-Export and Import
Final ppt of marketing research on jwellery industryptaakash
The Indian jewellery industry is an important and fast-growing sector of the Indian economy. It has two major segments - gold and diamonds. India has the largest diamond cutting and polishing industry in the world. It is also a major importer and consumer of gold and diamonds. The industry faces opportunities for growth in both domestic and international markets but also challenges from international competition and price fluctuations in gold and diamonds.
Titan Company Limited is celebrating its Unleashing Innovation Summit on December 1st 2016 to discuss its journey of innovation since its inception. Some key points in Titan's innovation journey include launching various watch brands starting in the 1980s such as Fastrack and Sonata, expanding into jewellery with brands like Tanishq, Goldplus, and Zoya, and establishing manufacturing facilities across India. Currently, Titan is India's largest watchmaker and jewellery retailer with over $2 billion in annual revenue. Titan believes innovation is driven by empowering employees, developing their skills, and having an open culture that encourages idea generation and calculated risk-taking.
Metallurgy is the process of extracting metals from ores and purifying them. It involves various physical and chemical steps. Key physical steps include crushing ores, concentrating them using processes like magnetic separation or flotation, and mechanically separating gangue from ores. Chemical steps include roasting or calcination to remove impurities, reduction of metal oxides using coke or other reducing agents, and electrolytic refining to obtain pure metals. The overall metallurgy process allows extraction of metals from ores on a commercial scale.
Nickel and its alloys, as well as titanium and its alloys, are important engineering materials. Nickel is a silvery white metal that is magnetic, hard, and ductile. It has many applications as an alloying element to produce alloys like Inconel and Hastelloy that are heat and corrosion resistant. Titanium is a strong yet lightweight metal that is highly corrosion resistant. It is commonly extracted from ores using the Kroll process and made into alpha, beta, and alpha-beta alloys for diverse applications like aerospace, industrial, automotive, and medical implants.
all the figures i have done that are from "Product design" by Kevin Otto and Kristin Wood.
I have conducted all sorts of engineering analysis and done the project.
Tailor welding blanks generally used for making doors of an automobile get crack along welding line. This leads to rejection and Wrong body production. Its analysis & countermeasure shared in sides.
The document discusses the refining and purification process of zinc. It begins with an introduction to zinc including its chemical formula, atomic number, and color. It then discusses the history of zinc discovery and production. The main uses of zinc are then outlined, followed by global zinc production and reserve statistics. The key steps in the zinc refining and purification process are then described in detail, including roasting, leaching, purification, electrolysis, melting and casting. Gas cleaning and sulfuric acid production are also summarized. Finally, the main applications of zinc in automotive, construction, hot dip galvanizing, and zinc castings are briefly outlined.
Manufacturing of Gold and Diamond Jewellery. Opportunities for Entrepreneurs to Start Own Business of Gold and Diamond Jewellery.
Jewellery or Jewellery consists of decorative things worn for personal adornment, similar to brooches, rings, necklaces, earrings, pendants, bracelets, and cufflinks. Jewellery could also be attached to the body or the clothes. From a western perspective, the term is restricted to durable ornaments, excluding flowers as an example. For many centuries metal, usually combined with gemstones, has been the normal material for Jewellery, however different materials similar to shells and other plant materials could also be used.
For More Details, Click Here: - https://bit.ly/2Zuj0LQ
Contact us
Niir Project Consultancy Services
An ISO 9001:2015 Company
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886
Mobile: +91-9097075054, 8800733955
Website: www.entrepreneurindia.co , www.niir.org
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
The document discusses the process of making steel, including the raw materials, production processes, and applications. Key points:
- Raw materials include iron ore, limestone, coke, and scrap metal. Iron ore is purified and melted in blast furnaces with coke and limestone.
- Primary production methods are basic oxygen furnace (BOF) and electric arc furnace (EAF), which further refine molten iron into steel.
- Secondary processes like degassing and temperature control produce semi-finished and finished steel products.
- Steel products have many applications in infrastructure, vehicles, machinery, and more due to their strength and cost effectiveness.
This document provides information about nickel, including its introduction, ores, extraction, alloys, and properties. It discusses that nickel was first isolated in 1751 and belongs to the transition metals. It has an FCC crystal structure and is both hard and ductile. The document also describes some common nickel alloys like Monels, Inconel 600, and Nichrome, providing their compositions, properties, and applications.
Copper is a reddish-colored metal with many useful properties and applications. It has a density of 8930 kg/m3 and melts at 1083°C. Copper occurs naturally and is extracted via mining and smelting. It has high tensile strength, ductility, and thermal and electrical conductivity. Copper is used extensively in building construction for roofing, flashing, gutters, pipes, wiring and more due to its durability, corrosion resistance and recyclability. Common copper alloys include brass and bronze.
The steel industry in India is affected by macroeconomic factors like GDP growth and inflation. Higher GDP growth leads to increased steel consumption for infrastructure and other sectors, fueling steel industry growth. However, high inflation has negatively impacted the steel industry by slowing growth in key customer industries like automobiles and construction. Rising inflation has also reduced consumer demand for housing and vehicles. The Reserve Bank of India's interest rate hikes to combat inflation have further raised borrowing costs, negatively impacting steel-intensive industries.
Ferrous metals are metals that contain iron, such as steel which is an alloy of iron and carbon. The amount of carbon determines the properties and applications of different types of ferrous metals. Pig iron contains a high amount of carbon (2-4%) and is very hard and brittle. It is used to make steel. Cast iron also contains 2-4% carbon and is strong under compression. Wrought iron contains a very low amount of carbon and is tough and malleable. Steel contains 0.15-1.5% carbon and includes low, medium, and high carbon varieties with different properties. Alloy steels like stainless steel add other elements like chromium for improved properties such as corrosion resistance. Fer
The automobile sector is a major consumer of castings produced in India. Currently, there are around 4,500 foundry units in the small, medium and large-scale sector. Out of these, 1500 units have international quality accreditation. Read More: https://bit.ly/2T9nh71
#marketresearch #marketreserachreport #foundrymarket #business
The document discusses the chemical properties of alkali metals. It explains that alkali metals react vigorously with oxygen and water. The reactivity increases down the group as the atoms get larger, shielding the outer electrons from the nucleus and making them easier to lose. Equations for reactions of lithium, sodium, and potassium with oxygen, water, and other substances are provided. Flame tests for group 2 metals are also discussed.
Dear Readers,
In this presentation, I have tried to explain main raw material sources of iron making process. Also, with my experience, I have tried to give a concept about the plant engineering related to raw material. I hope that, this presentation will be helpful for young engineers. With this presentation they will get a broad idea about the raw material, based on which they can study more on the subject.
Regards,
Nirjhar.
1). The document summarizes information about nickel, including its extraction from ores, properties, advantages, disadvantages, and classifications of nickel alloys. Nickel is extracted via pyrometallurgical or hydrometallurgical processes depending on the ore. 2). Important nickel alloys include nickel-copper alloys, nickel-chromium alloys, and nickel-base superalloys used in applications requiring high heat resistance. 3). Nickel has properties like corrosion resistance and is used to make alloys for applications across many industries.
Corrosion and corrosion inhibition of aluminum and aluminum alloys in acid me...mohammed rida
This document provides an introduction to aluminum, its key characteristics, aluminum alloys, corrosion of aluminum in acid solutions, and corrosion prevention methods. It discusses the low density, strength, corrosion resistance, conductivity, and other beneficial properties of aluminum. It describes common aluminum alloying elements like copper, magnesium, silicon, and their effects. The document also examines various types of localized corrosion that can affect aluminum, such as pitting, crevice, and galvanic corrosion. Finally, it outlines approaches for corrosion prevention, including alloy selection, coatings, use of inhibitors, and design considerations.
The document provides information on cast iron, including its history, manufacture, composition, types, properties, uses, production/processing, and future applications. Some key points:
- Cast iron was invented in China in the 5th century BC and has carbon content above 2%.
- It is manufactured by re-melting pig iron in a cupola furnace to remove impurities and produce molten cast iron for casting.
- The main types include grey, white, mottled, chilled, and spheroidal graphite (ductile) iron.
- It has properties of being relatively low melting, strong in compression but weak in tension, and not magnetic or ductile.
- Common uses include
IN THIS PPT U WILL LEARN ABOUT THE FOLLOWING SUB-TOPICS OF MANGANESE:-
-Uses
-Distribution
-Eco Significance
-Reserves in India
-Agencies exploring it
-Problems related to its exploitation
-Marketing and Production strategy
-Export and Import
Final ppt of marketing research on jwellery industryptaakash
The Indian jewellery industry is an important and fast-growing sector of the Indian economy. It has two major segments - gold and diamonds. India has the largest diamond cutting and polishing industry in the world. It is also a major importer and consumer of gold and diamonds. The industry faces opportunities for growth in both domestic and international markets but also challenges from international competition and price fluctuations in gold and diamonds.
Titan Company Limited is celebrating its Unleashing Innovation Summit on December 1st 2016 to discuss its journey of innovation since its inception. Some key points in Titan's innovation journey include launching various watch brands starting in the 1980s such as Fastrack and Sonata, expanding into jewellery with brands like Tanishq, Goldplus, and Zoya, and establishing manufacturing facilities across India. Currently, Titan is India's largest watchmaker and jewellery retailer with over $2 billion in annual revenue. Titan believes innovation is driven by empowering employees, developing their skills, and having an open culture that encourages idea generation and calculated risk-taking.
Metallurgy is the process of extracting metals from ores and purifying them. It involves various physical and chemical steps. Key physical steps include crushing ores, concentrating them using processes like magnetic separation or flotation, and mechanically separating gangue from ores. Chemical steps include roasting or calcination to remove impurities, reduction of metal oxides using coke or other reducing agents, and electrolytic refining to obtain pure metals. The overall metallurgy process allows extraction of metals from ores on a commercial scale.
Nickel and its alloys, as well as titanium and its alloys, are important engineering materials. Nickel is a silvery white metal that is magnetic, hard, and ductile. It has many applications as an alloying element to produce alloys like Inconel and Hastelloy that are heat and corrosion resistant. Titanium is a strong yet lightweight metal that is highly corrosion resistant. It is commonly extracted from ores using the Kroll process and made into alpha, beta, and alpha-beta alloys for diverse applications like aerospace, industrial, automotive, and medical implants.
all the figures i have done that are from "Product design" by Kevin Otto and Kristin Wood.
I have conducted all sorts of engineering analysis and done the project.
Tailor welding blanks generally used for making doors of an automobile get crack along welding line. This leads to rejection and Wrong body production. Its analysis & countermeasure shared in sides.
1. The project aimed to reduce sealing open rejection rates in film capacitors from 1.3% to 0.03% at Vishay componenets India pvt ltd, a manufacturer of semiconductor and passive components.
2. Data collection found the highest sealing open rejection rate of 1.28% was on Stella Romeo winding machines. Analysis identified loose compression springs causing the sealing pencil to become misaligned as the root cause.
3. Testing of different spring materials found Inconel X750 maintained its properties at operating temperatures. Implementation on all winding machines and standardization reduced the sealing open rejection rate to an average of 0.35%, meeting the project goal and saving $1.6 million
DESIGN AND FABRICATION OF AUTOMATED CRADEL MACHINEAaron Paul
A Project Report
Abstract :
A crank and kinematic links are designed in such way that it can be excited by electric motor for operating the automated cradle machine. By just switching ON the motor the cradle will swing and stops when switched OFF. This cradle is a typical one. This cradle varies from the traditional ones by hanging under the ceiling. This auto swing cradle is designed in such a way that it can be operated at a load of about 30 kg and the safety precautions are followed. This device is more compact and does not need any space on the floor. This type of cradle that hangs under the is the maiden attempt.
This document describes the design and fabrication of a wear test specimen die for metal matrix composite materials. It provides details of the project, including the equipment used for wear testing, die specifications designed using NX8 software, test specimen dimensions based on ASTM standards, the material selection and properties of oil hardened non-shrinking steel chosen for the die material, and the manufacturing processes employed to produce the die including casting, machining operations and electric discharge machining. The goal of the project is to produce a die that can be used to test the wear behavior of metal matrix composites.
The document provides information on weld repair, including the types of defects that can occur during manufacturing, the steps involved in deciding when repairs are needed, and how to execute welding repairs. It discusses inherent, processing, and service defects and their causes. The key steps in repair decision making are evaluating operating conditions, inspection history, reasons for failure, defect location using visual and NDT methods, and re-evaluating the need for repairs based on design calculations. When repairs are needed, the document outlines preparing the repair procedure, executing the welding according to qualified procedures while monitoring parameters, and inspecting the completed repair.
Report on Industrial visit at Aditya Auto products, Doddballapura, Bangalore.abhishekPatne2
1. Aditya Auto Products manufactures automotive components like window regulators, door latches, and cables.
2. The production process involves raw materials undergoing rolling, pressing, welding, and assembly into finished products.
3. Quality inspection and testing is conducted at various stages to ensure product quality meets standards before dispatch.
This document is a project report submitted by five students at the National Institute of Technology Raipur for their Bachelor of Technology degree. The report details a project to develop an association of a data acquisition system in a CNC machine for micro milling processes. The report includes an introduction on micro milling, copper machining, and data acquisition. It then reviews relevant literature, identifies problems with current micro milling processes like poor surface finish and lack of accuracy. It describes the experimental setup used and the process, with the goal of overcoming issues by integrating a data acquisition system to provide additional feedback parameters like cutting forces.
This document describes a project to analyze quality issues in products manufactured by an automotive parts company. It aims to identify the root causes of defects seen in rims, including root line defects, sheet faults, and side and root pits. Fishbone diagrams will be used to sort out the key issues. The document provides background on the company and analyzes defect data and trends over time. It identifies potential causes for grinding marks on rims, such as misaligned grinding equipment, worn parts, untrained workers, and excessive workload. Solutions proposed include automation of grinding and setting performance standards. A previous fishbone diagram for seam openings is also presented.
The pump has experienced erosion and requires extensive repair work. A new shaft will be manufactured along with new inter-stage segments, impeller neck rings, casing wear rings, and a Tuffnell bearing bush. The impellers and casing halves will be skimmed and rebuilt. Upon completion, the pump will be pressure tested and prepared for delivery back to the customer's plant.
Satyam Maurya presented on friction stir welding. The presentation covered the basics of friction stir welding including the process, microstructure, parameters, tooling, applications and advantages. Friction stir welding is a solid-state welding technique that uses a rotating tool to generate frictional heat and plasticize the materials being joined without melting them. It results in strong, high quality welds and is particularly useful for welding aluminum and magnesium alloys.
This document contains information about S.V. Alagarsamy, an Assistant Professor of Automobile Engineering at Shanmuganathan Engineering College. It provides details of his academic qualifications, including an M.E. in Manufacturing Engineering from Chendhuran College of Engineering and Technology and a B.E. in Mechanical Engineering from PTR College of Engineering and Technology. It also lists the subjects he has taught, including Engine & Vehicle Management Systems and Applied Thermodynamics and Heat Transfer. The remainder of the document covers an overview of manufacturing processes, specifically metal cutting theory, including types of machine tools and metal cutting processes, chip formation, cutting tool materials, tool wear, tool life, and cutting fluids.
Die design optimization and die stress analysis of control arm by simulation Kundan Kumar
The main objectives are as follows:
1.To develop a model for the automotive component “Control Arm”
2.To analyse the simulation trials
3.To optimize the Stress
The document is a report on the fabrication of a c-clamp submitted by engineering students at Cairo University. It describes the objective of making the c-clamp to learn manufacturing processes. It then details the processes used, including cutting the raw material to size, drilling a hole, and welding a nut. Dimensions of the finished part are provided. Photos show the different steps of rasping, drilling, and welding. Various welding processes are also defined.
Internship presentation at Fabrimax Engg Pvt Ltdabhishekgawande
This document summarizes an industry internship presentation by two mechanical engineering students at G.H. Raisoni College of Engineering. The presentation describes the fabrication processes at Fabrimax Engineering Pvt Ltd, where the students interned. It provides an overview of the company and its quality standards. Key fabrication processes like CNC cutting, three roller bending, and submerged metal arc welding are explained. Post-weld inspection techniques like dye penetrant testing, radiography testing, and ultrasonic testing are also summarized. A case study on using a robotic system for automatic ultrasonic weld inspection is presented to improve production quality and rates.
The document provides information on various aspects of spot welding including:
- Definitions of key terms like spot weld, welding control, and the importance of force between electrodes.
- Explanations of spot welding principles involving resistance heating when current passes through interfaces of stacked metals joined by electrodes applying pressure.
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Fracture analysis and defect reduction in passenger car rim
1. FAILURE ANALYSIS & DEFECT REDUCTION IN
PASSENGER CAR RIM
Team Members (BATCH-16)
1. Swaminathan.S 171001109
2. Tharun Kumar.C 171001111
3. Vignesh.S 171001116
Project type : Industry
Internal Supervisor : Dr.S.ARUMUGAM
Designation : Assistant professor
Organisation : SVCE
External Supervisor Name: Mr.V.SATHISH KUMAR B.E.,MBA.,
Designation : Senior Manager
Organisation : Wheels India Ltd.
2. S.No ACTIVITY
MONTH 1 MONTH 2 MONTH 3
FEB W3 FEB W4 MAR W1 MAR W 2 MAR W3 MAR W4 APR W1 APR W2 APR W3 APR W4
1 AIM AND OBJECTIVE
2 BASIC STUDY ABOUT M/C
3 DEFECT STUDY
4 CURRENT TREND ANALYSIS
5
TEMPERATURE BEHAVEOUR FOR
VARIOUS PARAMETER
6 MATERIAL STUDY
7 QUALITY PARTS VERIFICATION
8 IDENTIFYING THE CAUSE
9 DEVELOP SOLUTION USING DOE TOOLS
10
MONITORING RESULTS AND
COMPARING WITH PREVIOUS RESULTS
11 FINAL REPORT PREPARATION
LEGEND PLAN COMPLETED NOT COMPLETED
PROJECT PLAN
3. Wheels India Ltd.
Wheels India Limited is company promoted by the TVS Group, India’s
largest auto component manufacturers. Wheels India started
production of wheels for commercial vehicles in 1962 at our plant in
Padi, Chennai.
Products
Wheels
Air Suspension
Energy equipment parts
Heavy engineering
Fab division
Customers
Hyundai
Nissan
Toyota
Ford
Maruti Suzuki
Isuzu
PSA Citroen
7. Resistance Welding
• Resistance welding is the joining of metals by
applying pressure and passing current for a length
of time through the metal area which is to be
joined.
• The electrodes, typically manufactured from
copper based alloys due to superior conductive
properties, are cooled by water flowing through
cavities inside the electrode and the other
conductive tooling of the resistance welding
machine.
8. Flash (Butt) Welding
• Flash (butt) welding is an electrical resistance
welding processes used for joining components,
where the energy transfer is provided primarily by
the resistance heat from the parts themselves.
The components are positioned end-to-end across
the full joint area.
9. (a) (c)
(b) (d)
Electrodes
Position and Clamp the Parts
Apply Flashing Voltage
and Start Platen Motion
Flash
Upset and Terminate Current
The basic steps in a flash welding
sequence are as follows:
10. Flash Welding
Pros Cons
Flexible cross sectioned shapes
Produce unbalance on three-phase primary
power lines
Flexible positioning for similar cross section
parts
The ejected molten metal particles present a
fire hazard
Impurities can be removed during upset acts Require special equipment for removal of
flash metal
Faying surface preparation is not critical
except for large parts
Difficult alignment for workpieces with small
cross sections
Can weld rings of various cross sections Require almost identical cross section parts
Narrower heat-affected zones than those of
upset welds
14. Butt Welding Platen movement
11mm
BED GAP = 23mm
RETRACTION =2mm
FLASH = 6mm
UPSET =8mm
1
2
3
15. Machine and Rim Specification
S.no Main Parameters Data
1 Main circuit rated input voltage AC380V/1phase
2 Control circuit rated input voltage AC380V/3phase/50Hz
3 Secondary voltage 8.8V to 14.6V
4 Flash Current 450 Amps
5 Upset Current 1300 Amps
6 Upsetting pressure 45 bar (or) 652.67 psi
7 Clamping Pressure 65 bar (or) 942.74 psi(fixed)
8 Max welding cross section area 4000mm^2
9 Width of rim 200 mm
10 Thickness of rim 2.3 mm
11 dia of rim welded 350 mm
12 Cooling water flow rate 5000L/H
13 Pressure of cooling water 0.2-0.4MPa
14 Temp. of cooling water 28°C- 30°C
15 Rejection rate <= 0.5%
16. 3.Possible Defects
Failures caused during:
Butt welding Heeling Over Lap Butt weld fuse
Butt weld air leak Deep flash cut Flash cutting: Shallow Crack at coining
Crack at forming Crack at expanding Uneven flash cut
23. FUSE - DEFECT SELECTED FOR REDUCTION
Macro examination of weld taken near failure
Macro examination of weld taken away from failure
UNEVEN FUSION
OR UNBURN
MATERIAL IS
CALLED AS FUSE
DEFECT
26. 6.Material Study and Analysis
S.No
Mechanical properties Thermal Properties Composition
Ultimate
Tensile
MPa
Young’s
modulus
GPa
Brinnel
Hardnes
s
Yield
Strength
MPa
Latent
heat of
fusion
J/g
Meltin
g onset
˚C
Thermal
expansi
on
µm/mk
Density
g/cm^3
Carbon
%
Mangan
ese
%
1 440 190 130 270 250 1360 13 7.3 0.2 0.75
2 590 190 180 370 250 1420 13 7.8 0.09 1.69
27. Material Composition
Element C Si Mn P Al V Nb
%Wt 0.09 0.13 1.69 0.013 0.031 0.007 0.02
**NOTE:
Mn/Si < 25% (recommended)
Reason:
Increase in Mn/Si ratio increases the
brittleness of the material.
29. ULTIMATE STRENGTH ANALYSIS
TENSILE STRENGTH AND BENDING TEST
S.No SAMPLE UTS(MPa) Elang.(%)
BENDING
(TON)
BENDING
RESULT
1 OK PART 596.3 22 43 PASS
2 OK PART 602.5 28 42 PASS
3 OPEN CRACK 236.4 9.4 19.5 FAIL
4 OPEN CRACK 220.4 8.6 16.2 FAIL
5 FUSED 173.9 3.9 6.2 FAIL
6 FUSED 178.2 4.5 8 FAIL
30. 7.Q-PARTS VERIFICATION
S.No Points to be checked Checking method Frequency
1 Block bolt tightness Tight Daily
2 Grip bolt tightness Tight Daily
3 Ensuring lubrication in platen
arm connecting pin
Proper lubrication flow Daily
4 Hydraulic oil filtration Checking its color Daily
5 Spatter card No spatter accumulation
in ring to prevent short-
circuit
Daily
6 Tightness of electrical
connection ( Brider ) in
control panel
Check as per PM schedule Weekly
31. S.No Points to be checked Checking method Frequency
7
Clamp pressure for any
pressure drop
Maintain set value Daily
8
Upset pressure for any
pressure drop
Maintain set value Daily
9 Upset current Maintain set value Daily
10
Working of air cooler system
for heat control card in
welding control panel
Check temperature below
30 degree
Daily
32. 8.CAUSE AND EFFECT DIAGRAM
(Fish-Bone diagram)
Operator Skill
SOP & WI
adherence
Improper tool
setting
Upset pressure
High
low
Resistance in platen movement
Clamping pressure
Load variation in clamping
Poor conductivity
Current variation during flashing
Short circuit in machine
Bed gap variation
High panel temperature
Gap between block & block holder
Bed to bed height variation
Flaring % high in coning
Deep flash cutting
Rim got cold while flash cutting Excess edge cutting
Material out of squareness
Tool condition
Tool damage
Tool wear
Block to block height variation
Edge burr in slitting edge
Rusted material
Block and grip cumulative height variation
High
Low
Butt welding
Fusing issue
No. of suspected causes : 26
Bed to bed parallelism
Projection of packing
33. S.No CAUSES ACTION OBSERVATION RESULT
1 Operator skill
Operator skill level in skill
matrix
Welding is performed by trained
professionals
Ok
2 Improper tool setting
The set parameters must be of
the recommended values
The parameters are cross checked
twice with their spec within a shift
Ok
3 SOP & WI adherence Awareness of SOP & WI
The operators are interviewed about
SOP& WI and evaluated
Ok
4 Deep flash cutting
The thickness of the base
material to be checked after
flash cutting
It is checked using a thinning gauge
and measured ±0.1mm from base
thickness
Ok
5 Flaring % high in coning
Flaring % to be less than 10%
in coning
Wheel code wise flaring % is
checked and found to be les than
10%
Ok
6 Edge burr in slitting edge
The edges should be free of
burr
The strip is free of burr after
shearing the edges
Ok
7 Tool condition
The tool working condition
and contact surface must be
free of damage
The tool is checked and its in
working condition with no damage
to be found
Ok
34. S.No CAUSES ACTION OBSERVATION RESULT
8
Block to block height
variation
The block in the moving and
fixed plates should be of equal
height
Every block is checked of its height
in the tool room before setting fixing
it in the machine
Ok
9 Material out of squareness
The error in the squareness of
the material should be less
than 1mm
Squareness error checked during
slitting and found around 0.5mm
Ok
10 Rusted material
Material should be free of rust
in the welding edges and
clamping area
The material is checked and found to
be rust free
Ok
11
Block and grip cumulative
height variation
The block and grip height
placed together should be
between 102 to110mm
Their cumulative is measured in the
tool room and taped together as a
set
Ok
12 Upset pressure variation
Measure Upset pressure in
pressure gauge and pressure
accumulator gas pressure
The upset pressure remained close
to the spec and accumulator gas
pressure is 20 bar
Ok
13
Resistance in platen
movement
The smooth movement of
platen is required
The platen is moved manually and
the disturbance was checked using a
stethoscope
Ok
14 Clamp pressure variation
Measure clamp pressure in
pressure gauge and pressure
accumulator gas pressure
The clamp pressure remained close
to the spec and accumulator gas
pressure is 25 bar
Ok
35. S.No CAUSES ACTION OBSERVATION RESULT
15 Improper loading of band
Complete butting of band to
back stopper should be
ensured
The band butted properly in the
back stopper and no healing
occurred
Ok
16
Short circuit in machine
bed
There should be no current
flow in between weld beds
during open welding
The current flow is checked using an
ammeter
Ok
17 Poor conductivity No heat variation
The heat varied from time to time
during welding
Not ok
18 Bed to bed height variation
Bed to bed height variation
should be less than 0.5mm
It is checked using parallel block and
feeler gauge and 0.2mm variation
observed
Ok
19 Bed to bed parallelism
Bed to bed parallelism error
should be less than 1mm
It is checked using parallel block and
dial gauge and 0.7mm variation
observed
Ok
20
Gap between block and
block holder
This leads to poor conductivity
Gap found and improper block
seating found
Not ok
21
Heat control guard
temperature
Increase in temperature cause
malfunction of the device
leading to improper
temperature control
Interlock available for temperature
control
Ok
36. S.No CAUSES ACTION OBSERVATION RESULT
22 Bed gap variation
DOE TOOL TAKEN
FOR FURTHER
VALIDATION
23 Excess edge cutting
24 Projection of packing
25
Flash cutting after rim got
cold
26
Peak current in second
flash start
37.
38. 9.DOE TOOLS TAKEN FOR VALIDATING
THE PRODUCT DIMENSIONS
PRODUCT
SuspectedSources of
Variations (SSV’s)for the
physical phenomenonof
the problem
PC PPS CS MCS MVA CC VS FF OBS B VS C
Bed gap variation
Peak currentin second flash start
Projection of electrodepacking
Flash cutting after rimgotcold
Excess edgecutting
Machine
Method
PC – Paired Comparison, PPS – Product/Process search, CS – Component search MCS –
Modified Component search MVA – Multivari analysis VS – Variable search, FF – Full
factorial, OBS – Observation, CC – Concentration chart
39. DOE TOOL : PRODUCT/PROCESS
SEARCH TOOL
OBJECTIVE:
To Validate Machine & method related
Possible Causes.
Technique/Tool used:
Product/ Process Search Tool
RECORD THE SSV AND PROCESS COLLECT
8 GOOD AND 8 WORST SAMPLES
AND ARRANGE THE DATA IN
ASCENDING ORDER
WHERE COUNT SHOULD BE >= 6 FOR A
SIGNIFICANT FACTOR
40. DOE TOOL : PPS-Machine
Home Position Variation
(Set 23mm)
G 22.9
G 22.9
G 23
G 23.1
G 23.1
B 23.2
G 23.3
B 23.4
B 23.4
B 23.4
B 23.5
G 23.6
G 23.6
B 23.7
B 23.8
B 23.8
Count = 8
INITIAL BED GAP
/ PLATEN HOME
POSITION
Cause
No
What to
Verify ?
How Actual Observation Result
22
Bed gap
variation
PPS
(spec
±0.5mm
max)
Count = 8; Count
greater than 6 is a
contributing factor
NOT
OK
SIGNIFICANT
41. DOE TOOL : PPS-Method
EXCESS EDGE CUTTING
(mm)
B 8
G 8
G 8
G 10
B 10
G 11
G 11
B 11
G 13
G 13
B 13
B 14
G 15
B 15
B 15
B 15
Count = 3
Cause
No
What to
Verify ?
How Actual Observation Result
23
Excess edge
cutting
PPS
Count = 3; Count
greater than 6 is a not a
contributing factor
OK
Edge cutting
NOT
SIGNIFICANT
42. DOE TOOL : PPS-Machine
SHIM PROJECTING OUT
(mm)
B 3
G 3
G 3
G 4
G 4
G 4
B 4
B 4
G 5
B 5
B 5
G 5
B 6
B 6
G 7
B 7
Count = 1
Cause
No
What to
Verify ?
How Actual Observation Result
24
Projection of
electrode
packing
PPS
Count = 1; Count
greater than 6 is a not
contributing factor
OK
LOOSE PACKING
NOT
SIGNIFICANT
43. DOE TOOL : PPS-Method
RIM GOT COLD WHILE
FLASH CUTTING
(sec)
G 1
B 1
G 2
B 2
G 3
G 3
B 4
B 4
B 4
G 4
B 4
G 4
G 4
B 4
B 5
G 5
Count = 1
Cause
No
What to
Verify ?
How Actual Observation Result
25
Flash cutting
after rim got
cold
PPS
Count = 1; Count
greater than 6 is a not
contributing factor
OK
Rim should be in red
hot condition during
flash cutting
NOT
SIGNIFICANT
44. DOE TOOL : PPS-Machine
PEAK CURRENT IN
SECOND FLASH STARTING
G 250
G 250
G 250
G 275
G 280
G 300
B 500
B 500
G 500
B 600
B 600
B 650
B 650
G 700
B 700
B 720
Count = 7.5
Cause
No
What to
Verify ?
How Actual Observation Result
26
Current
variation
during flashing
PPS
(Variation in
current
during flash
change
over)
Count = 7.5; Count
greater than 6 is a
contributing factor
NOT
OK
Flash current
variation
SIGNIFICANT
45. DOE SUMMARY REPORT
Home Position
Variation
(Set 23mm)
G 22.9
G 22.9
G 23
G 23.1
G 23.1
B 23.2
G 23.3
B 23.4
B 23.4
B 23.4
B 23.5
G 23.6
G 23.6
B 23.7
B 23.8
B 23.8
Count = 8
SIGNIFICANT
EXCESS EDGE
CUTTING
(mm)
B 8
G 8
G 8
G 10
B 10
G 11
G 11
B 11
G 13
G 13
B 13
B 14
G 15
B 15
B 15
B 15
Count = 3
NOT SIGNIFICANT
SHIM PROJECTING
OUT
(mm)
B 3
G 3
G 3
G 4
G 4
G 4
B 4
B 4
G 5
B 5
B 5
G 5
B 6
B 6
G 7
B 7
Count = 1
NOT SIGNIFICANT
RIM GOT COLD
WHILE FLASH
CUTTING (sec)
G 1
B 1
G 2
B 2
G 3
G 3
B 4
B 4
B 4
G 4
B 4
G 4
G 4
B 4
B 5
G 5
Count = 1
NOT SIGNIFICANT
PEAK CURRENT IN
SECOND FLASH
STARTING
G 250
G 250
G 250
G 275
G 280
G 300
B 500
B 500
G 500
B 600
B 600
B 650
B 650
G 700
B 700
B 720
Count = 7.5
SIGNIFICANT
46. Why Why Analysis
Root Cause No: 17
Poor electrical
conductivity
Number of contacts
in current passage is
high
To achieve required
cumulative height
Bottom electrodes
are made of number
of layers
Block Assembly design
Counter measure: Block
assembly design to be
modified
47. Why Why Analysis
Root Cause No: 20
Gap between block
and block holder
Improper block
seating
Block has projected
packing
To achieve required
cumulative height
Block Assembly design
Counter measure: Block
assembly design to be
modified
48. Why Why Analysis
Root Cause No: 22
Initial bed gap
variation
Platen over travel
while return stroke
No control over
platen movement in
reverse stroke
Return stroke speed
is high and inertia
effect
Only one DC valve is engaged in return stroke
Counter measure: REVERSE
Flow control valve to be
engaged for reverse stroke
49. DOE TOOL : VARIABLE SEARCH TOOL
ROOT CAUSE NO: 26 (Current variation during flashing)
A
• 1st flash flow control in points
B
• 2nd flash flow control in points
C
• Heat control in %
Current
variation
50. DOE TOOL: VARIABLE SEARCH TOOL
No PARAMETER ( - Setting ) ( + Setting )
A 1st flash flow control 2.3 2
B
2nd flash flow control 1.2 1.5
C Heat control in % 85 78
Based on the experience, Parameters will be changed
FIRST LEVEL OPTIMAL SETTINGS
51. Test - Setting + Setting
1st Run 750 400
2nd Run 700 450
3rd Run 600 380
Median 700 400
Range 150 70
D ( Difference Between Two
Medians )
300
d = Average of Two Ranges 110
D/d 2.7
AS THE D/d RATIO IS > 1.25 , IT SHOWS THAT +SETTING
PARAMETER ARE EFFECTING THE RESPONSE IN POSITIVE DIRECTION
DOE TOOL: VARIABLE SEARCH TOOL
52. PEAK CURRENT IN SECOND
FLASH STARTING
G 250
G 250
G 250
G 275
G 280
G 300
B 500
B 500
G 500
B 600
B 600
B 650
B 650
G 700
B 700
B 720
Count = 7.5
Test - Setting + Setting
1st Run 750 400
2nd Run 700 450
3rd Run 600 380
Based on the Validation by PPS tool we
are getting GOOD samples when the
Current is below 300A.
So to Optimize the parameter 2nd level
Optimal setting parameter derived and
Revalidated with Variable search tool.
53. DOE TOOL: VARIABLE SEARCH TOOL
No PARAMETER ( - Setting ) ( + Setting )
A 1st flash flow control 2 1.8
B
2nd flash flow control 1.5 1.7
C Heat control in % 78 70
Based on the experience, Parameters will be changed
SECOND LEVEL OPTIMAL SETTINGS
54. Test - Setting + Setting
1st Run 450 200
2nd Run 380 250
3rd Run 450 200
Median 450 200
Range 70 50
D ( Difference Between Two
Medians )
250
d = Average of Two Ranges 60
D/d 4.16
AS THE D/d RATIO IS > 1.25 , IT SHOWS THAT +SETTING
PARAMETER ARE EFFECTING THE CURRENT VARIATION
DOE TOOL: VARIABLE SEARCH TOOL
55. No PARAMETER
BEFORE
( - setting)
AFTER
( + Setting )
A 1st flash flow control 2.3 1.8
B 2nd flash flow control 1.2 1.7
C
Heat control in % 85 70
SOLUTION FOR 26 : Parameter optimization to
avoid Flash current variation
56. SOLUTION FOR 17 & 20: Single piece block
replaced multi layered block assembly
BEFORE AFTER
Used Multi layered block
used with Top and Bottom
packing
(Up to 7 layers)
Single piece block used with
Top and Bottom packing to
reduce the conductivity
loss.(Maximum 3 layers used)
58. SOLUTION FOR 22 : Flow control valve engaged in reverse
stroke to avoid bed gap home position variation
BEFORE
There is no flow control valve
to control the flow for the
home position (Reverse
stroke). Due to inertia force
bed position getting varied.
59. SOLUTION FOR 22 : Flow control valve engaged in reverse
stroke to avoid bed gap home position variation
AFTER
Flow control valve
introduced in reverse
stroke to control the
return speed while return
stroke.
61. RESULT COMPARISON
PROPERTY BEFORE AFTER
DIFFERENCE
IN %
LP1401
SCRAP (PPM)
6263 947 84.87
PROPERTY BEFORE AFTER
DIFFERENCE
IN %
FUSE SCRAP
(PPM)
4626 204 95.59
95.59%
62. PROPERTY BEFORE AFTER DIFFERENCE IN %
SCRAP (PPM) 10059 4745 52.83
RESULT COMPARISON
The ring weld is illustrated in the above slide. Because the distance across the flash welded surface is shorter than the distance around the hoop, current tends to flow across the interface making the flash weld. However, a sizable amount of shunt current follows the path around the hoop, thus higher currents are generally required when shunt paths like this are present. Often, the preheat cycle is eliminated as this would tend to preheat the entire part and additional heat at the interface would raise the resistance there and force more shut current into effect.
Three common types of welds made by flash welding are shown in this and the following two slides.
The axially aligned weld is shown in the above slide.