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Aditya Report DDS P-3 Cell
Aditya Report DDS P-3 Cell
INTERNSHIP REPORT
By
Aditya Deokate
1
P-3 CELL
CERTIFICATE
Netaji Pawar
Mfg. Dept.
2
P-3 CELL
Acknowledgement
ADITYA DEOKATE
3
P-3 CELL
INDEX
Table Index
1 Operations Sequence 10
4
P-3 CELL
5
P-3 CELL
2. Introduction of Departments
6
P-3 CELL
3. Manufacturing Department
7
P-3 CELL
4. Problem Statement
Dent marks are observed on casting of P-3 cell i.e. CT 100 crankcase casting.
The castings are made of aluminium alloy material. Various processes such as
Milling, Drilling & Tapping, Bore finishing are performed on the casting on CNC
Milling machines. During this processes the face resting on the resting pad is prone
to dent marks. These dent marks on crankcase are undesirable as they may later
create a problem of oil leakage or oil starvation. Thus this increases the rejection of
the cell which in turn increases the revenue losses. Along with dent damage, issue
of handling damage also needs to be reduced.
5. Introduction
When machining brass, copper or aluminium alloys, it is noticed that the part
has dents when it was clamped during the CNC milling process. Dent marks are the
small indentions on the machining surface. Dent marks occur due to various reasons
such as high clamping pressure, remains of burr on fixture, ineffective flushing by
coolant, etc. Generally, it is observed that when burr remains on fixture and new job
is clamped on the fixture then due to the clamping force the burr trapped between
resting pad and resting face creates a dent mark on the resting face of the casting.
Dent marks on aluminium alloy die casting are smooth dents on most of the thick
surface of the die casting. This increase the rejection of material. The root cause
being the burr remaining on fixture or on the casting increases the chances of dent
mark. Thus, reducing the amount of burr remaining on fixture or the casting can
significantly reduce the chances of dent mark. This can be achieved by regularly
cleaning the fixture, considering all design attributes of fixture design and effective
flushing of the casting during the machining process which will ensure that
maximum burr is flushed out with the coolant. Fixture design attributes such resting
pads, dowel, supporting blocks design play important role. Hence to reduce dent
mark on casting, a complete root cause analysis is needed to be done. This project
consists of various studies which helped to identify contribution of various factors
in dent damage study.
8
P-3 CELL
VMC=11,
Rough Rough
HMC=2, Full Finish & R-Face
Boring Boring
Washing=1
Total=
14
Cell-A
↑ ↙ ←
←
M4022
M490 M489
OP30 RH & LH ← OP20 LH ← OP10 LH
Makino
↑ ↙ ← Cell-B
M4023
M0474 M0486
OP30 RH & LH ← OP20 LH ← OP10 LH
Makino
1m42s 2m26s 3m6s
70/hr 36/hr 34/hr
←
Final
→ Washing → Gauging → Inspection
9
P-3 CELL
10
P-3 CELL
OP-20
R.H L.H
HSSE Roll Tap M8*1.25 6H SH8 SQ6.2 OL90 SC Drill D5.48*D55FL*110 OAL
OP-30 OP-40
D100 Milling Cutter PCD Reamer D36*22SL/D41*110 OAL SHK D20
PSSC Drill D7.35*25SL*D9*40FL*100 D52 P6 Remax Head
NTC
PCD Reamer D10H8 SH10 OAL95 PCD Reamer D8*15 BLA LEN*35FL*80
HSSE Roll Tap M8*1025 6H SH8 SQ6.2 D4 Identification Drill
OL90
SC Drill D5.48*D55FL*110 OAL HSSE PCD Reamer D16H8 * 180 OAL Shank DAH81
Roll Tap M6*1P 6H SH6 SQ4.9 OL80
D12 CHFR Tool PCD Reamer D13*D32*D40
- D52 H7 Remax Head
- PCD Reamer D28 P6* 40FL *OAL100*SH20
- PCD Reamer D8*14/D13*16/D22*OAL
125SHD20
- PCD Reamer D13*D24*D32*D40
- PCD Reamer D108.0H8*5.5SL*150 *96OAL Z4
- Reamer PCD D10 H8 FL15 SH D12-OAL 100
Table 2.3. OP-30 & OP-40 Tool Specs.
11
P-3 CELL
1 1 2
2 3
1 4
A
12
P-3 CELL
13
P-3 CELL
E1 - - - - - -
E2 - - - - - -
E3 - - - - - -
E4 - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 1 - - - - 1
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 - - - - - -
H3 - - - - - -
H4 - - - - - -
TOTAL 1 1 1 1 -
Table 3.2. Operation wise Dent Mark B-Cell (RH)
14
P-3 CELL
E1 - - - - - - -
E2 - - - - - - -
E3 - - - - - - -
E4 1 - - - - 1
F1 - - - - - 1 1
F2 - - - - - - -
F3 - - - - - - -
F4 - - - - - 1 1
G1 - - - - - - -
G2 - - - - - - -
G3 - - - - - - -
G4 - - - - - - -
H1 - - - - - - -
H2 - - - - - - -
H3 - - - - - - -
H4 - - - - - - -
TOTAL 1 2 2 4 - 2 11
Table 3.3. Operation wise Dent Mark A-Cell (LH)
15
P-3 CELL
E1 - - - - - -
E2 - - - - - -
E3 - - - - - -
E4 - - - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 - - - - - -
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 1 - - - - 1
H3 - - - - - -
H4 - - - - - -
TOTAL 1 1 1 2 - 5
Table 3.4. Operation wise Dent Mark B-Cell (LH)
16
P-3 CELL
17
P-3 CELL
E1 - 15 - - - -
E2 - 22 - - - -
E3 - - - - - -
E4 - - - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 - - - - - -
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 - - - - - -
H3 - 25 - - - -
H4 - - - - - -
TOTAL 43 62 0 0 0 0
18
P-3 CELL
19
P-3 CELL
9. ANALYSIS
A set of processes were followed in order to complete the Dent Mark Study.
This included dent mark position identifying, which helped to find the major
contributing operation. Then burr trapping study was conducted to identify
the locations at which burr/chips were remaining after each operation.
Followed by this clamping and resting locations were traced. It was found that
the location’s at which burr was trapping, dent marks generally occurredat the
same milling face locations. This included various drill holes and dowel holes
near the clamping and resting pad locations.
Based on daily inspection data, the dent damage daily trend was observed.
This included data from 17th March to 30th April. The results came out are
summarized below.
12.00
11.08
10.00 9.58
8.76
8.41 8.42
8.02
8.00 7.67
7.10
6.65 6.68
6.06
6.00 5.51
5.21
4.94
4.73 4.78 4.56 4.69
4.42 4.25
4.14
3.77 3.81
4.00 3.56 3.53
3.07 3.23
2.83 2.74 3.00
2.71
2.20 2.33
1.91
2.00
1.10
0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00
Percentage
20