Upload
bachayadav
View
225
Download
1
Embed Size (px)
Citation preview
7/27/2019 ICS Report On Onkar Furnitech
1/16
(DEPARTMENT OF MECHANICAL ENGINEERING)
SESSION 2013-14
INDUSTRIAL CASE STUDY REPORT ON AGROFAB
MACHINERIES PVT. LTD., HINGNA, NAGPUR
SUBMITTED BY:
NAME OF STUDENT ROLL NO.
1) AKSHAY KALAMBE 232) AMIT SAWARKAR 243) AMIT YADAV 254) AMIT PARDHI 26
GUIDED BY- PROF. R. S. SHELKE
7/27/2019 ICS Report On Onkar Furnitech
2/16
INDEX PAGE
Sr. no.
1 INTODUCTION
2 PROBLEM IDENTIFICATION
3 PROCESSES UNDERTAKEN
4 MACHINES USED
5 INSPECTION AND SAMPLING
6 PACKAGING AND TRANSPORTATION
7 CASE STUDY
8 SOLUTIONS
9 CONCLUSION
10 GROUP PHOTO
11 ACKNOWLEDGEMENT
7/27/2019 ICS Report On Onkar Furnitech
3/16
1 .INTRODUCTION
AGROFAB MACHINERIES PVT. LTD. is a reputed industry in MIDC area at Hingna Road
Nagpur. The main outputs of the industry are machined parts for tractors of Mahindra &
Mahindra Tractors located at Nagpur. Over the years company has successfully provided the
required tractor assembly parts to the company and is continuing their good streak in
manufacturing industry. The company has been able to accreditation of ISO 9001:2000. The
various products under its manufacturing hoods are:
a) C. V. Cylinder Head
b) Differential Gear Housing
c) Distributor Housing
d) Valve Body
The company has very high quality CNC machines from AMS synchronized with Distributed
Control System from FANUC. With this quality of machines hardly there are any mistake that
could happen during manufacturing. Though we have tried to make an effort and found out some
problems that could be solved by certain easy measures, thus helping factory to save time and
labour.
Agrofab Machineries (I) Pvt Ltd. is one among the very few Critical Component manufacturers
of Hydraulis & Tractor transmission. It started its journey in the CNC machining field since
FY2000, with a small machine shop catering one of the Hydraulic component for Mahindra
Tractors Ltd. & today it is the largest manufactures of these hydraulic & transmission
manufacturers. Also, they have established their own foundry with the Capacity 500MT per
month at Nagpur; The parts produced are mainly supplied to Mahindra & Mahindra Tractors Ltd
& Eicher Tractors Ltd.
ADDRESS: W - 119/120 M.I.D.C Hingna Nagpur - 440016
WORKERS: 25
7/27/2019 ICS Report On Onkar Furnitech
4/16
1.1ORGANISATION STRUCTURE:
The structure of organization is primarily hierarchical. The organization structure of industry
is given as follows:
Flowchart1: Organization structure of industry
7/27/2019 ICS Report On Onkar Furnitech
5/16
2.PROBLEM IDENTIFICATION:
During the case study,certain problems were identified.They are:
1.Problems during machining processes:
Drill breakage Chipping of corner edge Chipping of cutting edge Abnormal wear on corner part Large wear and chipping, crushing of the chisel edge
2.Blind boring:-
A through bore was sunk across the thickness of the part.
3. In a certain operation of control valve cylinder head of the particular diameter
was getting oversize.
4.Chip disposal.
3.PROCESSES UNDERTAKEN:
Fig.1: Visual inspection of materials
Inspection of raw materials: Here temporary inspection of raw materials is done. Just byfinding any visual defects.
http://www.carbidedepot.com/formulas-drills-troubleshoot.htm#drillbreakagehttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#chippingofcorneredgehttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#chippingofcuttingedgehttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#abnormalwearoncornerhttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#largewearandchippinghttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#largewearandchippinghttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#abnormalwearoncornerhttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#chippingofcuttingedgehttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#chippingofcorneredgehttp://www.carbidedepot.com/formulas-drills-troubleshoot.htm#drillbreakage7/27/2019 ICS Report On Onkar Furnitech
6/16
3.1 PROCESS FLOW CHART:
Flowchart2:Processes carried out
7/27/2019 ICS Report On Onkar Furnitech
7/16
3.2 PROCESSES UNDERTAKEN
Facing: It is operation of moving the cutting tool at right angle to the axis of rotation of therotating work piece.
Spot facing: It is machining operation where material is removed from surface to make it flatand smooth, usually for fastener or bearing.
Drilling: It is used to remove material from the inside of a work piece. Reaming: It is used to create an accurate size hole. Threading: It is the process of creating a screw thread.
4. MACHINES USED:
Different types of machines from conventional drilling to CNCs both kind of machines can be
found in this plant.Some of those machines are stated and their purpose is explained below:
4.1 CNC Lathe:
Fig.2: CNC lathe machine used in the company
7/27/2019 ICS Report On Onkar Furnitech
8/16
The machine is controlled electronically via a computer menu style interface; the program may
be modified and displayed at the machine, along with a simulated view of process. The
setter/operator needs a high level of skill to perform the operation, however the knowledge base
is broader compared to the older production machine where intimate knowledge of each machine
was considered essential. These machines are often set and operated by the same person where
the operator will supervise a small number of machines.
4.2 CNC Milling:
Most CNC machines are computer controlled vertical mills
with the ability to move the spindle vertically along the Z-axis,CNC machines can exist in virtually any of the forms of
manual machineries, like horizontal mills. The most advanced
CNC milling machines, the multi axis machines, add two more
axes in addition to the three normal axes (XYZ). Horizontal
milling machines also have a C or Q axis, allowing a
horizontally mounted workpiece to be rotated, essentially
allowing a symmetric and eccentric turning. The fifth axis (B
axis) controls the tilt of the tool itself. When all of these axes
are used in conjunction with each other, extremely
complicated geometries, even organic geometries such as a
human head can be made with relative ease with these machines. Fig.3; CNC Milling machine
But the skill to program such geometries is beyond that of most operators. Therefore, 5-axis
milling machines are practically always programmed with CAM.
7/27/2019 ICS Report On Onkar Furnitech
9/16
4.3 Milling Machine:
A milling machine is a machine tool used is machine solid materials.
Milling machines are often classed in two basic forms, horizontal
and vertical, which refer to the orientation of the main spindle. Both
types range in size from small, bench-mounted devices to room-sized
machines. Unlike a drill press, which holds the workpiece stationary
as the drill moves axially to penetrate the material, milling machines
also moves the workpiece radially against the rotating milling cutter,
which cuts on its sides as well as its tip. Workpiece and cutter
movement are precisely controlled to less than 0.001 in (0.025 mm),
usually by means of precision ground slides and leadscrews or
analogous technology. Fig.4:Milling machine
4.4 VMC Machine:
Features of VMC are:
1. Fully tooled up solutions to meet the customer needs &Tool life management.
2. Chip Conveyor3. High speed spindle up to 12000 rpm with chillier
Flood Coolant System.
4. Coolant through Spindle.5. Centralized & Programmable Lubrication6. Carbide tool is generally used.
7/27/2019 ICS Report On Onkar Furnitech
10/16
5.INSPECTION AND SAMPLING:
An inspection is most generally an organized examination or formal evaluation exercise. It
involves the measurements, tests and gauges applied to certain characteristics in regard to an
object and activity. The results are usually compared to specified requirements andstandards for
determining whether the item or activity is in line with these targets. Inspections are usually non-
destructive.
In this industry various types of gauges to maintain accuracy and precision at various stages of
machining are performed. Each stage involves checking of dimensional accuracy. The
commonly used gauges at plant are:
a) Go-Nogo gaugeb) Calipers (inside caliper, vernier caliper)c) Micrometer screw gauged) Pneumatic gauge
Fig.6:Inspection using pneumatic gauge Fig.7: GO-NOGO gauge
7/27/2019 ICS Report On Onkar Furnitech
11/16
6. PACKAGING & TRANSPORTATION:
Fig.8: Transportation of fial product
The final product after going through inspection & sampling is oiled for protection against
corrosion. And then product is finally packed inside a plastic bag. Thus the final product is ready
to be transported to other industry.
7. CASE STUDY:
The case study was carried out at AGROFAB MACHINERIES PVT. LTD., MIDC,Hingna Road, Nagpur.
The raw material was provided by Mahindra & Mahindra procured from casting unit atChennai.
Various machining processes are carried out to make casting fit to use. The plant runs 24 hours a day. The production work is carried out in 4 shifts and each
shift consist of 6 hours.
The production rate of the industry is 800 parts per day.
7/27/2019 ICS Report On Onkar Furnitech
12/16
8.SOLUTIONS:
1. .Problems during machining processes:
Problem Causes Solutions
Drill breakage In accurate machine
Work material deformation
Increase the rigidity of machine, drill and work
clamping
Relief angle is too small Regrind correctly
Feed rate is too high Decrease the feed rate
Excessive tool wear Regrind
Chip packing
Select suitable drill (wide flute, high helix oil hole
drill). Change cutting conditions (feed rate or adoptstep drilling).
Difficulty entering thematerial
Select high rigid tool & rigid machineIncrease work clamping rigidity
Select a low cutting resistance thinningUse centeringWork piece should be horizontal
Use bush drill
Problem Causes Solutions
Chipping ofcorner edge
In appropriate tool material Choose suitable tool material
Uneven hardnessdistribution on the work
material
Iso static treatmentChange tool, material & cutting conditions,
machining method (EDM)
Cutting or feed speed is toohigh
Reduce cutting speed or feed
Not enough coolant Change lubrication method
Problem Causes Solutions
Chipping of
cutting edge
Large run out after attached
to machine
Loose hold
Check holder and/or select another oneCheck run out after fixing to the chuck
Relief angle is too small Regrind correctly
Tool material is not
suitableChoose suitable tool material
Cutting speed or feed is too
highReduce cutting speed or feed
Problem Causes Solutions
Abnormal wear
on corner part
Tool late regrinding Regrind after a shorter time of use
Bad alignment (for latheturning)
Check/adjust the alignment
Cutting speed too high Decrease the cutting speed
Point dimensions are notsuitable
Select correct point dimensions
Tool materials not suitable Choose suitable tool material
7/27/2019 ICS Report On Onkar Furnitech
13/16
Problem Causes Solutions
Large wear and
chipping,
crushing of thechisel edge
Feed rate is too large Decrease feed rate
Point dimensions are not
suitable Select correct point dimensions
Tool materials is notsuitable
Choose suitable tool material
Relief angle is too small Increase relief angle
Problem Causes Solutions
Chipping of
margin
Bush diameter is too small
Chip packing between drill
& bush
Select correct bush diameter or select drill with chip
breakers
Problem Causes Solutions
Margin built-up High heat generation due tolarge wear on the cutting
edge
Regrind
Problem Causes Solutions
Tang breakage
Shank slippage due to some
kind of defectTake off the defect by honing the surface
Defect of the inner surfaceof Morse taper holder
Change holder or correct the surface of Morse taperholder
Low accuracy of regrinding Regrind correctly
Problem Causes Solutions
Noise ofchattering
Relief angle is too big Grind a smaller relief angle
Low rigidity of the tool Use drill with high rigidity
2 .BLIND BORING
Bore was required only upto a certain depth.That process was unnecessary and wasconsuming more time,power and labour.
This could be overcome by just attaching a sttoper to the drill bit at the optimum requiredlength.This will reduce time,save,labour and avoid unnecessary wearing of tool.
7/27/2019 ICS Report On Onkar Furnitech
14/16
3. .DIAMETER GETTING OVERSIZE
Fig.9:Diameter of cylinder valve head getting oversize
For this we have checked the run out of the tool. Afteranalyzing the problem after deep studies,we came to a solution.The raw material used here isgrey cast iron.
For machining of cast iron does not need any coolant, it may be cut in dry condition. As inour case also, the operation for drilling and hole milling kept as in dry cutting condition.
As the property of the cast iron is to produce dust with small flakes of chip,such dust get fly off along with current air by the fans put in the shop floor & get
accumulated everywhere.
In-due course of time this dust get accumulated on the taper of the tool holder & causes tohave run out in the tool. As the tool run out
increase the bore to become oversize.
All the taper of the tools & the spindle to be clean after every 12 hours. Air connection was given through the spindle to blow off the dust in thespindle taper for accumulating it.
7/27/2019 ICS Report On Onkar Furnitech
15/16
4. CHIP DISPOSAL
Centralized chip disposal system can be suggested over this system.
We suggest that chip disposal can be carried out by a conveyor chip disposal system. Thissystem will run periodically to carry the chips to disposal area,
9.CONCLUSION
The various departments of the industry were visited.Each
and every process such as fiishing,drilling,milling etc. were observed and studied carefully.We
discussed the importance and objectives of the processes being carried out.During the case
study,some problems were identified related to machining processes,machines,chips etc.We
discussed these problems with the engineer and workers of the company.The solutions,according
to our opinion, were provided.
We have tried to find the solutions of the problems which
were identified in a view to help to enhance the working of the company.
10. GROUP PHOTO:
7/27/2019 ICS Report On Onkar Furnitech
16/16
NAME OF STUDENT
1.AKSHAY KALAMBE (A-23)
2 .AMIT SAWARKAR (A-24)
3. AMIT YADAV (A-25)
4. AMIT PARDHI (A-26)