HYDRAULIC EJECTION SYSTEM

FOR CORE
A Project By,
Mr. DHERE N.B.
Mr. MANDE S.G
UNDER THE GUIDENCE OF
Prof. A. V. NANDGAVE

PROJECT WORK PLACE

TATA MOTORS
JAMSHEDPUR

PUNE

SANAND

LUCKNOW

CHINCHWAD

PIMPRI

AUTO DIV.

TAL

CAR PLANT

APD/RATP

ERC

FOUNDRY
G.I.FOUNDRY
H.P.M.

MELTING

SAND PLANT

CORE SHOP

FETTLING

FOUNDRY CORE SHOP

SHELL CORE BLOWER MACHINE

EXISTING EJECTION SYSTEM

Pneumatic ejection system
System was part of core box
Pneumatic ram ejection system in following core boxes.

1.4 DICOR BLOCK WATER JACKET CORE BOX SET 1

1.4 DICOR BLOCK WATER JACKET CORE BOX SET 2
1.4 DICOR BLOCK WATER JACKET CORE BOX SET 3
2.2 DICOR BLOCK WATER JACKET CORE BOX SET 1
2.2 DICOR BLOCK WATER JACKET CORE BOX SET 2
2.2 DICOR BLOCK WATER JACKET CORE BOX SET 3
2.2 DICOR BLOCK WATER JACKET CORE BOX SET 4
4 DL BLOCK WATER JACKET CORE BOX SET 3
4 DL BLOCK WATER JACKET CORE BOX SET 4
486 MAGNA BLOCK WATER JACKET CORE BOX

EXISTING EJECTION SYSTEM

All core boxes are having inbuilt ram ejection system.
4 nos. pneumatic cylinders are mounted on core box.

CORE
BOX

EXISTING EJECTION SYSTEM

Cylinder operation is pneumatic & cylinder seal kit is made up of

asbestos rope.
CYLINDER

PISTON

ASBESTOS SEAL

PROBLEMS WITH EXISTING SYSTEM

During production, many times, pneumatic cylinder

seals are getting leakage due to high temperature i.e.

300C & cylinder not operates properly

Core rejection is in higher side.

Core getting stuck up into ram due to failure of cylinder,

while breaking core in ram half, under cuts are formed in

core box.

Replacing of seal i.e. down time is in higher side.

FAULT FINDING BY USING QUALITY TOOLS

BRAINSTORMING
Changing of seal material
Use of spring loaded ejection system.
Pneumatic ejection system of core box.
Improve surface finish of ram half of core box.
Change of process parameter i.e. temp., curing time, etc.
Interchange of ram half cavity to door half cavity.
Remove deposits from core box at regular intervals.
Change the sand used for cores.
Cleaning of core box regularly.
Lack of knowledge among peoples.
Change of sand resin.
Change of sand grain size.

 CAUSE & EFFECT DIAGRAM :

MAN

MACHINE
Regular
operator

Lack of knowledge

Process parameter
Change of
parameter

Change of sealing
Change of resin

CORE STUCK
TO RAM SIDE
Spring ejection

Pneumatic ejection

MATERIAL

METHOD

ROOT CAUSE
After analysis we have find the root cause of the problem
i.e. Ejection system.
Hence we discussed with company peoples and finalized the
solution i.e. HYDRAULIC EJECTION SYSTEM
Why hydraulic system?
Because in the machine already hydraulic drive is used for following
motion
1) Ram forward & retract motion
2) Door open & close motion

HYARAULIC EJECTION SYSTEM

Space limitation for mounting of hydraulic cylinder

RAM OR
FRAME

HYARAULIC EJECTION SYSTEM

CYLINDER TAKEN FOR TRIAL

( OD=65mm,Stroke=25mm,ID=40mm)

AVALIABLE SPACE FOR CYLINDER

IN RAM BORE
(ID=90mm & Length=100mm)

HYARAULIC EJECTION SYSTEM

CYLINDER MOUNTING PLATE

CYLINDER MOUNTED WITH

PLATE ON RAM

HYARAULIC EJECTION SYSTEM

NEW DESIGNED CYLINDER ACCORDING TO AVAILABLE SPACE

HYARAULIC EJECTION SYSTEM

GUIDE ROD & BUSH MOUNTING PLATE WELDED TO THE RAM.

Spacer (OD=50mm & L=100MM

HYARAULIC EJECTION SYSTEM

EJECTION PINS GUIDED FROM

HEATER PLATE DRILLED
HOLE

EJECTION PINS PUSHING POINTS

ASSEMBLY OF HYARAULIC EJECTION SYSTEM

ADJUSTABLE
SPACER
GUIDE ROD
& BUSH

EJECTION
PLATE

CORE BOX
WITH
HEATER
PLATE

PERFORMANCE OF
HYDRAULIC EJECTION
SYSTEM

COMPARISION OF CORE REJECTION TREN

PRODUCTION TARGET:
90 CORES/SHIFT & 250 CORES/DAY

Approx. 3 nos. cores/shift &

8 nos. cores/day

Approx. 1 nos. core/shift &

2 nos. cores/day

FEATURES OF HYDRAULIC
SYSTEM

EJECTION

Cost effective and alternative to pneumatic system.

High volume of production with minimum rejection.
Quality of core improved.
Rejection of core reduced.
Hydraulic cylinder force makes operation smooth.
Less temperature affects to the system hence less maintenance.
Low manufacturing cost and ease of maintenance.
Reduces maintenance cost, rejection cost, labour cost.

FUTURE SCOPE
To minimize the heat transfer rate we can do the following improvements:
Refractory material to be added in between the joint of hydraulic cylinder
and ejection.
Asbestos material to be added on backside of the heater plate so that
heat transfer from heater plate to the hydraulic cylinder can be
minimized.
Development of the hydraulic seal material for sustaining the high
temperature.

THANK YOU