UNDER ABLE GUIDANCE OF:- A.K SANGHI (HEAD OF R&D) AND Mr. GOPAL KRISHNA (PROD. MANAGER) SUBMITTED BY:- Name :- SUKHWINDER SINGH Roll no.:- 11103317 College -UCOE,PUNJABI UNIVERSITY PATIALA ee creed 7 eePLANT INTRODUCTION @ FEDERAL MOGUL MOGUL GOETZE () LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of Piston Rings for | automobile industry in 1957. Considering the need of complete PISTON assembly ESCORTS LIMITED | ventured into manufacturing of Pistons.In 1958 with the collaboration of M/S MAHLE GmbH, GERMANY, | which delivered the Indian automobile industry its Piston in 1960. ESCORTS entered in collaboration with M/S SUKO GmbH, GERMANY, for Piston Pins in 1967 and manufacturing started in 1968. The plant manufacture over 3.4 million & 29 million Piston-Pins & Crank Pins annually Around 50% of its production is being fitted by original equipment manufactureres of Automobile, Bi-wheelers, Tractors, Stationary Sees, Generator etc. biggest customers are the MUL for which it manufactures pistons for Maruti-800, Esteem, Zen etc. Otfer customers include Peugot , Escorts Division-Faridabad, Bajaj, Vespa, Hindustan Motors , TVS lany Others . The company also directly supplies products to all authorized dealers of the spare rts/of all the above companies throughout INDIA.BRIEF ABOUT ALL WORK STATIONS HS DEPARTMENT.- This department checks that the industry is working within the norms of pollution control board and that no part of the factory in anyway effecting the environment. The EHS department | looks after the environment conservation by making the organization compatible to ISO 14001 which gives the requirements for environmental management systems, confirms its global relevance for arganizations wishing to operate in an environmentally sustainable manner. For examale in order to comply with the above mentioned, we have a total of males tesatg paints in our plant. It also looks after the safety aspect of all the employees by supplying them with [al Equipment ) and instruction fora safe working environment, PURCHASE DEPARTMENT.- It purchases items from local market against purchase requisitions to meet day- to- day requirements in variaus departments. It has the following respansibilities:- Supplier Selection eveinetien| purchese of material, Devalapmant of exsting suppliers including OMS (Guu te Management’System) development , Purchase of capital equipment process maps test PPE (Personal Protective repaired or made new in this department. To avoid undue delay in the repair of break down of machinery, new foyhdry tooling (dies) or jiq and fixture are required to facilitate production are also manufactured in this tog room FINANCE DEPARTMENT. Finance department maintains account books concerned with finance and disburses salary to workmen, junior staff and releases payment to outside parties. There is another degartment within this, which works out the costing data of products ie. pistons, piston rings, pins and infarms marketing for the finalization of product with the customers. Apart tromthie it has the responsibility of salaries, MIS Reporting , Balance Sheets, Statutory Audits, Income taxing, Accounts payable and Excise calculation.BRIEF ABOUT ALL WORK STATIONS ) PMS DOMESTIC:- It Comprises 16 Production Lines For Manufacturing Blanks .The Lines From 1to12 Can Be | Distinguish Individually by the Size of Pistons and Machining Operations but these pistons referred as | OE(Original Equipment) . Pistons Dispatches from line 14 to 16 to customers are referred as AE(After Market) . EXPORT PISTON:- It comprises Cells rather than the Line as I already mention latterly about the another department They manufactured Forged piston which is to be handed over a single employee in Cell. FOUNDARY%- In Foundry Shop Blanks Of Pistons are To Be Casted by Gravity Die Casting Pracess Despite They have Internal Lab Facilities For Assuring the Composition Of Alloy . Furthermore, they also have Heat Treatment Facilities which relieve internal defects of alloy and improve its strength LB: This department have new technology which is ta handed over the quality of the pistons They also Designing ing designing \Topling DesigningPISTON MANUFACTURING PROCESS (STANDARD) EST FOR FeQ LEVEL 1 PISTON Ne MACHINING DEG _—.) CALCULATIONS a MODEL 5 MODEL SERVICES(RDS) ~ DESIGN ON Ne! “ DRAWING REVEW /* FEA ANALYSIS MANUFACTURE PARTS.PISTON MANUFACTURING PROCESS (RING CARRIER) Plunge Rough = | | eutting/Ri Roi ( Blanks from ‘ eae — Fixture Seat Overturning Pre Pin Hole Forming, Bottom j——» Crown in fle Foundary Machining (Under Thickness & Rough Faci 5 ms L Design Limits) | / Qverturning Rit Oil Hole Aluminium eons aren OF } Drilling Grooving eet foe 7 Bin Hole eC ag ‘ Dia. — f Ciretip | Grooving & Pin Rolling & Phosphating & or * ole = 7% Cleaning *} Moly Coating v _ Chamfering LePMS DOMESTIC (LINE-2 BLOCK DIAGRAM) = MOGUL pom BLANKS FOUNDARY FOUNDARY STANDARD TOOL USED TEGN CNUK,TPGN,THMA PMTM/C LM-491 M/C FIXTURE | ‘SIMULTAENOUSLY (PLUNGE CUT) GUIDE SLEEVE , DRIVING (PLUNGE CUT) LOADED PIECE , HOLLOW CENTER MEASUREMENT GAUGES TOOL USED TOOL USED CARBIDE BIT Toot. cuMw / P\ GRAZED ON i PMT M/C SHANK,TPGN FIXTURE fe PMIMEE : (ROUGH BOTTOM/CROWN |. rece | (KDYFIXTURE SEAT M/cing) wl Face) HOLDING JAWS & DRIVING PIECE TOOL useD ‘CARBIDE TIPPED DRILL(RCMT).HSS ORILLWD-4/a162 1 WE-2 MIC 2 : (PREBORING) FIXTURE ic ROUGH BORING cl FIXTURE,ORIVING PIECEPMS DOMESTIC (LINE-2 BLOCK DIAGRAM) @ FEDERAL MOGUL TOOL USED MEASUREMEN OIL HOLE DRILUING M/C) Cianx (oT) GAUGES PCD ALL TOOL USED i) ‘ACE-FANUC SIRIEN smuriano ipshcisiy | eneTuRE {ALUMINIUM GROOVING) - DRIVING PIEGE & FINISH TURNING ‘SIEMENS JYOTI M/C PCD ,CARBIDE TIP CHAMFER , NEX-110 M/C eel tse (RING CARRIER GROOVING & ‘CHAMFERING) TOOL USED * PCD &DIAMOND (UREA) = crite: 200.085 * CCGT-NSERT (CCGT USED FOR TOP PORTIN FINISHING ANE PROFILE MAITAININGPMS DOMESTIC (LINE-2 BLOCK DIAGRAM) + PCD DIAMOND + CT-4/699 ,CT-31102 ~~EIXTURE | + BORING MANDREL + “BLOCK LESLE EES Or TOOLUSED I ciao + PCD CT-31130 : ae + PCD & CARBIDE BIT me ECCENTRIC ROM FEMCO -CAVITY MIC ' “EE TUN (ccenRiccavTY, © |“ swutamousty (ECCENTRIC CAVITY FORMING) \oaneD FORMING) ‘ TOOL USED-CARBIDE = CT-3891(ROUND WIRE) ————~s= CT-3/892(FLAT SURFACE) = CT-31082(TRAPEZ SURFACE) MACHINED STOCKIN TRAYS a A c JORNAL-1,GEN~4461 ROLLER Itrepresents the upgraded machine 7 which causes bottle neck error and now it was upgraded with new technolog | ie a} iNEX-110,FANUC (ALFIN GROOVING M/C) Itis bring into your notice that this machine is used for ALFIN grooving (Ring Groove Formation) .For this operations of profile generation we are using KEYSTONE GROOVE with different profile as on the basis of required groove profile ) ‘Solution after Trials:- Recently, we have achieved our target in optimizing the cycle time from 68-69sec/job to 45-47sec; jab unit.NEX-110,FANUC (ALFIN GROOVING M/C) NC FUNCTIONS SINGLE BLOCKOPTIONAL BLock ——MACHINE LOCK SKIPOPTIONAL STOP PROGRAM CHECK —/ SKIPBUTTON —- CHIP CONVEYOR AUTO, FOR WARD.STOP,REVERSE PARTS CATCHER out _ eae TAIL SPINDLE eretoeroe qa SeME Feed Axis SelectNEX-110,FANUC KEYSTONE GROOVE on the basis customer requirements we are using different kinds of KEY STONE GROOVE which assists | in improving the quality of product and its running circumstances . Following three KEY STONE GROOVE | are used for ALFIN Grooving CARBIDE (a) CARBIDE (b) CARBIDE (c) Full Key Stone Half Key Stone Key Stone Tool Cost = Rs360/piece (approx.) Holder Cost = Rs 1000 (approx.) Too! life = 500/job unitMETHODOLOGY USED IN ALFIN GROOVING © ALFIN GROOVING (Plunging Method):- Full Key Stone/Half key Stone/Simple is used for ALFIN Grooving .By this method rough cut is drawn by keystone before profile formation and easily | cut the unwanted amount of material as on the basis of design PIN HOLE TAILSTOCK CENTERING NEEDLE Topl is used for PLUNGING METHODMETHODOLOGY USED IN KEYSTONE GENERATION METHOD = KEYSTONE GENERATIVE METHOD :- In this method Half KEYSTONE Groove for straight cut and | CBN is used for making the ALFIN Profile finish and cutin under control limits .This task of | profile generation is done through programming which assist tool and easily follow the track. PERIPHERY OF PISTON END POINT ALFIN GROOVE PROFILE = | woe OF PISTON “Sc fo START POINT fo ‘| GENERATIVE TOOL re (CBN) / Tool takes two steps to cut groove profile Cl Ring Carrier piston ove Forward start and proceed into with a cutting stroke from start point upto End 4) Another step used to make for inclined flank by providing required path through yrdming for the movement of cutting toolRESEARCH WORK AND TASK CONCEPTUALISATION © FEDERAL = Technology Up-gradation of Line-2 . - | Why ItIs Needed - As this is for your awareness that Line-2 is an old Production Line but supplying OE | (Original Equipment) parts to customers like Sonalika , Eicher , Tata, Cummins etc. Quality maintenance is an indispensable part of organization to uplift the expectations of customers by providing assurance . It improves the quality and productivity of product which attains a benchmark to the competitors inside the market . ‘Quality Lag :- Blow by issue during engine working which reduces the horse power and life of piston . ‘Causes of high blow by :-(a) Poor groove roughness fo (b) Burrs present at the Groove Flank. (c) Poor Tool life on Grooving operation. So , It iso be bring into your notice that 1* and last points are interlinked . - Groove Burrs problem can be solved by changing the layout and processes of Line-2.STRATEGICAL TRIALS ON KEYSTONE GENERATION METHOD = | Cutting Tool Used :-CARBIDE TRAPEZ TOOL For Rough cut whose RPM = 450, FEED = 0.03MM and CBN Tool For Finish cut whose RPM = 1200, FEED = 0.04 MM RESULT :- Angular profile of groove flank not straight . IN TAKEN 3 (a) Tool adjusted to correct angle but same result i {b) Tool checked and found o.k. {c) Tool holder to be changed / Groove tool cleaned & remounted , Groove tool change. NO IMPROVEMENT :- Clamping Pressure reduced from 9 kg/em2to7kg/cm2. 10%IMPREVEMENT :- RPM = 1500, FEED = 0.05 ,Clamping Pressure = 7kg/cm2, 15% IMROVEMENT 4:-RPM = 600, FEED = 0.03 MM ,Clamping Pressure = 7 kg/cm2 , 30% IMPROVEMENTSTRATEGICAL TRIALS ON KEYSTONE GENERATION i (a). Geometrical parameter to be restored first , M/c checked for alignment & found 25 micron out, Jalignment correct ‘on 6/2/2014. (b)Centre drilling on KD2F operation was observed 0.2 mm out M/c handed aver to maintenance department & needle bearing changed » After maintenance at KD2F , center concentric was still upto 70-80 microns . » Piston made on CI grooving with 70 micron center concentricity . After then center concentricity was correct groove geometry & groove straightness is upto 13 micron. f 20 pistons made after correcting KD2F Center concentricity upto 70 micron Machine was allowed to run for further 100 pistons to validate the results But Tool got Break till 38 piston because eye piece opened . + Spindle orientation and fixture clamping was at M&F type.STRATEGICAL TRIALS ON KEYSTONE GENERATION METHOD ‘ool holder needs to be adjusted for reverse spindle orientation and Rough carbide tool have to be | reversed for making Trapez Form. | | From Batch of 50 pistons two were taken with mark of 1 & 50 and then Dispatch to LVD-Metrology Lab (for CI Groove Angle Inspection) . Both were accepted as on the basis of repart decision (Roughness, waviness , Groove angle) Trial 1 :~ After changing the Carbide Toal a sample is to be made and inspected in Quality Assurance Department (Roughness , Waviness) and later dispatch ta LVD-Metrology Lab(Groove Angle) NOSTRATEGICAL TRIALS ON KEYSTONE GENERATION METHOD © » Recently we have changed the techniques of groove generation method with the current one | which compnises of groove toolPROCESS IMPROVEMENT © Generation Method for Alfin Groove Machining. taditionally , Key stone groove was being achined by Plunging Method with carbide Method was introduced to produce groove with CBN groove tools. CycleCUSTOMER SATISFACTION Or | Prevention of Burr on ALFIN Groove Flanks.COMBUSTION BOWL MACHINING BY PLUNGING i This is traditional method used for _carburetion neration but now its use is obsolete vl | area : PMS-Domestic. As this machining is to be done in small steps which should clear you inside the figure . The Form cuts the bowl profile and generate straight profile Mostly there were 8-9 steps for this operation which was helpful for carrying most of load wibration during machining and avoid Tool CARBIDE (FORM TOOL) needs to be operate at low RPM and less Ro! Lifg. Its creates bottle Neck which makes effects the fate of production.COMBUSTION BOWL MACHINING BY GENERATION © Generation method is introduced in Finish Cavity operation thus elimination of carbide form tools wided:- tool provided for both Rough and Finish Guts to /praduce bowl thus enabling high speed Rachinifig and increased Tool Life. Machining Time @duce fo 42 sec. Too! Cost = Rs5000 (approx.) Holder Cost = Rs5500 (approx.PMT M/C :- TNMA Tool replaced with TPGN. This Upgradation of technology is to bring into the notice | that TNMA tool has six cutting edges used for machining the job But with the passage of time, wear and | tear per edge causes remounting the insert during each time of loading and unloading. This kind of bottle | neck & ergonomics factor is rectified by altering the cutting tool technology with the current one. Therefore | we have proposed TPGN tool (PCD tool) having single cutting edge but 4 to 6 times more life than TNMA tool ADVANTAGES: M/C setup time reduced . Tool life increased e reduced reduced by 5 sec saved upto certain units.Twin Carbide Inserts used for Turning Life = 500/Edg New PCD Insert (TPGN) Life =20000 inserts were being used for thing on Plunge cut operation p of 50O/edge only. 2 inserts d for turning the piston. New PCD insert installed for rough turning operation with tool life up to 20000 thus reduced cost/piston and reduced Tool change loss. Cycle time is also improved by 5 sec. with further scope of improvement.TECHNOLOGY UPGRADATION (PMS DOMESTIC, LINE-2) @ FEDERAL MOGUL * | In this latterly we were uses Carbide bit brazed on shank part but now its use obsolete because we would | like to exchange this insert with the TPGN tool (PCD) which have more life than the carbide insert . Lapping is not required after 500 pistons Tool life extended up to 15000 pistons Cycletime reduced by 4-5 sec ic=) Onl Carbide form tool acing costs around 5000Rs. duires regrinding after every 's thus more tool change loss stipart. Secondly plunging of ool causes lot of vibrations in achine thus frequent spindle for PCD TOOL FOR ROUGH FACING OPERATONS ‘Old Carbide Form Tool Life =500 Life =20000 New PCD Insert (TPGN) |. New PCD insert costs 2200 Rs. And tool life is 20000 thus reduced too! change and cost/part. No vibrations at all during operation thus improved machine spindle life. Cycle time is reduced by 5 sec with further scope of improvement.RESEARCH WORK AND TASK CONCEPTUALISATION @ FEDERAL MOGUL ecently, we were replaces triangular insert with pentagonal which was costlier and less life than the | Pentagonal insert. Before the commencement of research work we were uses the new CBN Tool and | Pentagonal insert for further improvement in process work . | * We-drawn out three scrap pistons for setting of machine as per in accordance with changes and we were found following results: Piston 1_:- After machining with current setting dimensional error occurs after calibration on gauges STEP DIA,GROOVISH & ALFIN Internal Diameter were not under design limits b) Piston 2 :- Besides ,dimensional error try to remedied by altering the coordinate system with small changes but during calibration it causes i error al internal diameter of ALFIN Groove . Cost =Rs?800 ¢) Piston 3 :- Furthermore ,with small altercation inside cutting position of tool we were calibrate it but GROOVISH not in our design limits . 2 * Last piston dispatched to LVD for precise inspection of Groove Angle and found to be 7°26'14* but company requirements bAw 7°10" to 7°40. So, it was found o.k ROUGH CUT FINISH CUT Pressure = 7Kq/om? Straightn #371 RPM = 350 RPM = 1280 Fa =0.55y Feed =0.050mm Feed =0.035mmRESEARCH WORK AND TASK CONCEPTUALISATION © FEDERAL MOGUL eeping RPM & FEED Rate same Altering pressure to 10Kg/cm* and another piston drawn out for sample inspection . This was dispatched to FMR for ROUGHNESS which seems to be 0.55y and for STRAIGHTNESS: | inspected inside LVD which was found to be 2.3y + | Mext day two sample were drawn out for angle inspection and dispatched to FMR . Groove Taper Report Obs. Drop Obs Angle Obs. Drop Obs Angle 1 134.90p 7°45'10" 12.83 0°10'47" 133.04y 7°38'43" 5.57y 0°9'34" on¢lusion:- Improvement not observed .RESEARCH WORK AND TASK CONCEPTUALISATION e Another come etor piston of USHA brand manufacturers was taken out for precise inspection of Angle, A iness. We were calibrating it by Vernier caliper because there was no fixture for this ene seat Diameter and we found as shown below:| RESEARCH WORK AND TASK CONCEPTUALISATION e | WAVINESS :- en position error rectify by analyzing during production which was hit directly to the job, when fromits rest position to cutting position This position was altered by altering the position of the cutfing tool otherwise tool breakage occurs .RESEARCH WORK AND TASK CONCEPTUALISATION e FEDERAL Product Type -EICHER TCI Machine Name:-NEX-110-104401929 a :- 56sec 1.(Piston1) 2.(Piston 25) 045 45 260/390 3.{Piston 35) 0.33 45 394 7°28' -0.10 #0 4(Piston45) 036 +5 393 7°28" -0.10 #0 5.\Piston70) 0.34 +4 393 7°28' -0.10 -0.14 6(Piston 100) 0.35 +5/+4 393 7°29" -0.16 +0.07 7APiton 112) 0.36 +5 395 7°28' -0.12 +0.08RESEARCH WORK AND TASK CONCEPTUALISATION FEDERAL * At Piston 121 there was error occurs in its straightness and generation stop at 145 but at Piston 140 Straightness observed as shown below on report basis : n> Generation stop for same improvisation and further improvement in its process work .As this is bring into your notice that the operation which was used latterly is an old processes and recently itwas upgraded with new hnology .TP'GN taal changed with TNMA which has more life than latterly used tool and also with use of this tool cycle time reduces tom imin2sec to 42 sec. ADVANTAGES: Tool life increased Cost per Ped reduced . Cycle timg reduced by 5 sec Tool Life= Rs3300/piece Holder Cost= Rs5600/- SIDE VIEW FRONT VIEW TOP VIEW VAN[ASK CONCEPTUALISATION MANFACTURED PRODUCTS (PMS DOMESTIC, LINE-2) © FEDERAL _DERS eS | SONALIKA 3] FARMTR TATA SEIMENS a" EICHER INTERNATIONAL