INTRODUCTION TO THE

PROJECT

One of the sole purpose of Mechanical Engineering is to:

Develop and optimize various manufacturing processes & developingnew and more economically viable manufacturing processes.

We have incorporated various techniques of CAPP (Computer AidedProcess Planning ). One such vital and very much trending tool is LeanManufacturing process

PROBLEM STATEMENT

• What are the main drawbacks of traditional forging techniques?

• Obsolete furnace design using fossil fuel to heat hardly up to 900 c but has efficiency of about 30 %

• High fuel consumption rate decrease the profitability.

• Inconsistent and non uniform heating.

TRADITIONAL FURNACES• Non green process.• Waste disposal and furnace

maintenance.

INDUCTION HEATING - THE LEAN

GREEN ALTERNATIVE

AIM OF THE PROJECT

• By implementation of induction technology

• Decreasing lead time of production

• Optimized consistency

• Maximized productivity

• Improved product quality

• Environmentally sound

• Reduced energy consumption

“SEMI AUTOMATIC FORGING WITH

INDUCTION TECHNOLOGY”

The entire project can be classified intothree sub chapters and will be discussedone after another as follows:

• Induction heating system

• Semi automatic Forging press system

• Automatic Robotic Handling system

INDUCTION HEATING SYSTEM

HYDRAULI

C PRESS

FORGING

UNIT

ROBOTIC MANIPULATOR

INDUCTION HEATING

APPLICATION

INDUCTION FURNACE

INDUCTION WELDING

• INDUCTION BRAZING

INDUCTION SEALING

HEAT TREATMENT

APPLICATION CONTINUED

• Forging industry application.• Automotive and aerospace Industry Solutions• Power Generation Industry Solutions• Oil & Gas Industry Solutions• Food Industry Heating Solutions• Cable and Wire Heating Solutions• Medical Device Manufacturing Solutions

THEORY

• Important Factors to Consider• METAL OR PLASTIC• MAGNETIC OR NONMAGNETIC• THICK OR THIN• RESISTIVITY• Inductor Design• Power Supply Capacity• Degree of Temperature Change Required

IMPORTANT FACTORS TO BE CONSIDERED

Material Final temp.°C Efficiency

Carbon steel 1250 0.65

Carbon steel 700 0.80

Stainless steel 1250 0.60

Brass 800 0.50

Copper 900 0.40

Aluminum 500 0.40

efficiency of heat transfer in induction heating

FREQUENCY SELECTION FOR GIVEN DIAMETER AND TEMPERATUE

• (1) From vacuum tube oscillator and electronic generator

• (2) From spark-gap generator• (3) From motor-generator set• (4) From solid-state inverters

TYPES OF POWER SYSTEM

IGBT is the most suitable to be used as a power source.

GOVERNING EQUATION

SKIN DEPTH AT GIVEN FREQUENCY OF CERTAIN MATERIAL

SIMULATION RESULTS

INDUCTOR DESIGN

• Material : copper• No . Of turns :6• Diameter of rod: 3 mm• Applied frequency : 160 khz• Temp of work piece : 900 degree C• Electrical rating:220v ,10 A• Time of heating: 30sec• Power consumption : 2200 KW

Before calculating our energy requirements we first need to know:

• • The type of material (steel, copper, brass, etc.)• • Work piece dimensions• • Desired hourly production• • Desired final temperature

VIDEO ON HEATING

Hydraulic press forging system

• What is Press Forging?

definition:• The shaping of metal between dies by mechanical or

hydraulic pressure. Usually this is accomplished with a

single work stroke of the press for each die station.

Working principle of press

FORGING FORCE

DIE DESIGN

DESIGN

All dimensions are in inch

Robotic manipulator

JOINT

ACTUATOR

Controller

ROBOTIC ARM DESIGN

ROBOT Geometry

FANUC code for the desired movement

• SPEED 60 • JOINT A1= 80.67 A2= -59.22 A3= 81.58 A4= -0.15 A5= -19.51 A6= 5.76 • GRIPPER OPEN • JOINT A1= 80.67 A2= -50.15 A3= 72.51 A4= -0.15 A5= -19.51 A6= 5.76 • GRIPPER CLOSE • SPEED 90• JOINT A1= 2.15 A2= -63.5 A3= 75.52 A4= -0.15 A5= -0.97 A6= 5.75• JOINT A1= 2.15 A2= -55.29 A3= 67.31 A4= -0.15 A5= -4.64 A6= 5.76• WAIT 30000• JOINT A1= 2.15 A2= -72.34 A3= 84.36 A4= -0.15 A5= -4.63 A6= 5.76• WAIT 60000• SPEED 100• JOINT A1= 79.78 A2= -64.23 A3= 80.56 A4= -0.15 A5= -4.64 A6= 5.76• JOINT A1= 79.78 A2= -59.32 A3= 75.65 A4= -0.15 A5= 62.19 A6= 5.76• WAIT 20000• GRIPPER OPEN• WAIT 1000• HOME_ALL

• Video

THEORITICAL ECONOMIC ANALYSIS:

Parameters Conventional forging Process:

COST Induction forging process:

COST

Production time.

90 min ----------- 35 min --------

Lead time : More Less

Fuel consumption :

8-10 Kg coal + fuel oil+Auxiliarymachinery cost

Rs 4@ RS 400/ ton coal+ RS 5 + Rs 6 =Rs 15

Electricity=1.16 KWh + .54 Kwh

Rs 8.50@ Rs 7/ kWh

Polluting gases: Present Non green Absent Green

Accuracy : 30% ------------ 80% -----------

Efficiency : 40% ------------ 75% ------------

Rate of production:

LOW HIGH

For making 10 square section from round bar by a single worker we adopted two procedure for a study :

PROBLEMS WE MAY ENCOUNTER

• High initial cost of implementation.

• Critical electronic solid state circuit .

• Resonance matching required to get desired heating effect.

• Skilled work force .

FUTURE SCOPE

• It is a new and emerging field in modern manufacturing technology.

• Ample scope of research and development with the coil design , die design , and implementation of automation.

• Portability can be increased.

• Response to different material can be studied.

• Experimental validation of certain hypothetical statements can be verified.