ics report on onkar furnitech

7/27/2019 ICS Report On Onkar Furnitech

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(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


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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


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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


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1.1ORGANISATION STRUCTURE:

The structure of organization is primarily hierarchical. The organization structure of industry

is given as follows:

Flowchart1: Organization structure of industry


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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#drillbreakage


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3.1 PROCESS FLOW CHART:

Flowchart2:Processes carried out


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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


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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.


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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.


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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


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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.


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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


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


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


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


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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


Chipping of

margin

Bush diameter is too small

Chip packing between drill

& bush

Select correct bush diameter or select drill with chip

breakers


Margin built-up High heat generation due tolarge wear on the cutting

edge

Regrind


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


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.


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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.


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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:


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NAME OF STUDENT

1.AKSHAY KALAMBE (A-23)

2 .AMIT SAWARKAR (A-24)

3. AMIT YADAV (A-25)

4. AMIT PARDHI (A-26)

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