MEDICAPS INSTITUTE OF TECHNOLOGY AND MANAGEMENT

INDUSTRIAL TRAINING ATAVTECH Ltd.

Submitted To Submitted ByDr. K.K. Gupta Shivam PandeyHead of Mechanical Dept. (0812ME111094)

AIM

Identification of Sources of Leakages of Hydraulic & Neat

Cutting Oil on 16T Broaching m/c (RG+SL Broaching machines)

The Broaching Machine – A Brief Introduction

• Broaching is a method of removing metal by pushing or pulling a cutting tool known as broach which cuts in fixed path.

• Surfaces finished by broaching may be flat or contoured and may be either internal or external.

• Broaching is generally limited to the removal of about 6mm of stock or less.

• The machine which performs broaching is known as the broaching machine.

• The broaching machine is probably the simplest of all machine tools. It consist of a work holding fixture, a broaching tool, a tool drive mechanism, and a suitable frame.

• It consist of one or more rams depending upon the production requirement.

• Dual ram models are arranged so that when one ram is on the cutting stroke, the other is on the return stroke.

• The return stroke is performed quickly to gain time, which is used to unload and load the machine.

• Broaching machine usually pull or push the broach through, or past a workpiece that is held in a fixture.

• Most broaching machines are hydraulically operated to secure a smooth & uniform action.

The Broaching machine

Cutting Oil Pipe

Base Plate

Broaches

Sources Which Are Identified

• The cutting oil gets sprinkled from the working area to the back side of the machine.

• Oil leakages were found at the joints of the hydraulic pipes.

• Oil goes out with the chips via conveyor in the chip trolley.

• Cutting oil adheres to the material and goes into the bin along with the material.

Source no. 1

The cutting oil gets sprinkled from the working area to the back side of the machine.

Reason of Spillage

• When the machine is switched ON and when the broach starts cutting the material, lots of cutting oil is used in order to cool the material and the broach.

• The cutting oil is also used for the lubricating and cleaning purposes.

• This cutting oil comes out of a pipe and is made to spill on the broach and the material.

• This oil coming out of the pipe gathers in the working area and slowly goes into the oil tank.

• During cutting, the chips also goes into the oil tank with the oil.

• This sometimes blocks the oil passage and therefore the oil starts pouring out of the cutting area and out of the machine.

• During cutting the area where the material is kept is filled with the chips and it needs to be cleaned after every cutting cycle.

• During this cleaning, the cutting oil splash out of the machine.

• When the broach cuts the material, it creates some vibrations in the machine and due to this vibrations, some oil splash out of the machine.

Actions taken in order to prevent the spillage

• A metal guard is made in the shape shown in the figure.

• This metal guard is placed in front of the operator and behind the broach.

• When the cutting oil gets sprinkled, the metal guard stops it from going out of the working area and thus the oil goes straight to the cutting oil tank.

Metal Guard

Source no. 2Oil leakages were found at the joints of the hydraulic pipes.

Reason of Spillage

• While the machine is working it undergoes a lots of vibrations due to the cutting of the material by the broach. Due to this vibrations the joints of the hydraulic pipes gets loose and thus oil starts leaking from this joints.

Actions taken in order to prevent the spillage

• At first we cleaned all the hydraulic pipes properly with the help of cotton.

• Now we start working on the machine.• If there are any leakages in the pipes it will be

easily observed now.• By this way we indentified the leakages.• All the joints where there were leakages are

tightened and thus leakages were prevented.• Some minor leakages can be prevented by

applying a sealant at the joints.

Source no. 3Oil goes out with the chips via conveyor in the chip trolley.

Reason of Spillage

• While the machine is cutting the material, the chips also goes into the cutting oil tank along with the cutting oil.

• This chips needs to be carried out of the cutting oil tank in order to prevent contamination.

• This chips are carried out of the oil tank via a magnetic conveyor through which the chips goes into the chip trolley

• But while the chips are coming out of the oil tank, some amount of oil also gets out of the tank and goes into the chip trolley along with the chips

Actions taken in order to prevent the spillage

• Since the oil coming out of the tank with the chips cannot be stopped, therefore we needed to do something in the chip trolley itself.

• A filter can be provided over the chip trolley so that the oil can go through the filter in the trolley which further can be poured out into the oil tank.

Source no. 4Cutting oil adheres to the material and goes into the bin along with the material.

Reason of Spillage

• While the machine is working we provide a lot of cutting oil to the cutter(broach) and material.

• This cutting oil after the process is done adheres to the material.

• This material when carried out of the machine contains some amount of oil adhered to its surface.

Actions taken in order to prevent the spillage

• The material after cutting should be hanged onto some hinged pin so that the adhered oil on the material gets drained.

• The material after cutting should be placed somewhere and should be kept there for a particular amount of time to get drained.

Disadvantages of leakages

• Due to the leakages the oil is wasted and hence it increases the cost of production.

• Leaked oil mix with the chips and dust and thus contaminate the area.

• Leaked oil on the ground can make the surface slippery.

• Mixture of oil and dust affects the working of machine and its accessories.

• Leakage of oil will require more cleaning of the machine and the area and thus increasing the cost of maintenance.

Conclusion

Apr May Jun Jul Aug Sep Oct Nov Dec

40 100 100 90 20 40 40 40 80 80

0 0 0 0 0 0 0 0 0 0

190 320 200 70 140 40 80 120 180 300

40 0 100 40 120 40 25 80 80 195

0 0 0 0 0 0 0 0 0 0

190 180 200 140 120 180 400 240 370 240

Monthly Oil Consumption Report - 2013~14

Monthly PlanOil Consumption in Ltrs.

EP-68 is the Hydraulic OilILO BROACH NO. 11 is the Cutting Oil

Oil Consumption (in Lit.)

Conclusion

• After performing various activities defined above ,we have identified every possible source of consumption of hyd. & cutting oil in the broaching machines. This sources are now prevented by applying various actions discussed above. By preventing all this sources, we will reduce the consumption of the cutting and the hydraulic oil upto 20~25% and finally reduce the cost of the production.

Thank you