Ashoka.docx

ASHOK IRON WORKS PVT LTD.

CHAPTER 1 INTRODUCTION TO COMPANY 1.1 Company profile Ashok Iron works was founded in the year 1974. By Mr. Ashok S.Humbarnadi. It is one of the leading Industries. Currently Ashok Iron Work Company holds the fourth place in leading job foundries in India. In fact AIW is one of the very few foundries which is QS-9000 certified. The company has appointed a marketing consultant in Germany for developing new over customers. Sector

-

Material

Industry

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Iron and steel

Sub industry -

Iron and Steel foundry

Area

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18600 (sq. metre.)

Man Power

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500 (one plant Jai Hind Eng.)

Total Plant

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14 (In Belgaum Only)

Chairman:

Mr. Ashok S. Humbarnadi

Joint Managing Director:

Mr. Jayant Humbarnadi

Director:

Mr. V. S. Katkar

Address - Mazagaon Road, Udyambag, Belgavi, Karnataka, India 590008. Phone - 0831-2442599 Fax

- 0831-2441899

Website - ashokiron.com

1.2 Main Features of Company   

ISO-9000 company Implementation of Kaizen Principle Implementation of Poka Yoke Implementation of 5S tools

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1.3 Customers Plant: Ashok Iron Works Unit-III  TAFE 1. Transmission Case 2. Centre Housing  ESCORT 1. Axle Housing 2. Front Engine Support  1. 2. 3.

MAHINDRA & MAHINDRA MMTC (Transmission Case) VTU HSG (Hydraulic lift housing) H2 CL HSG (Clutch housing)

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1.4 Process Flow Diagram

CASTING FROM FOUNDRY VARIOUS MACHINING OPERATIONS on CRANKSHAFT

FINISHED PRODUCT

CLEANING AND INSPECTION

DISPATCH

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CHAPTER 2 MACHINING OPERATIONS Below operation are given sequentially done on CRANKSHAFT (KV12/16) to produce final product.

2.1 Operation No1: Connecting Pin Milling              1. 2. 3.          

Machine Name: GFM MACHINE Machine type: Special Purpose Milling Machine Operation: Connecting Pin(cp) Milling Machine description: Cutting speed:250 rpm Feed:160mm/min Timing: Initial setting 5:05min Machining time: 62:12min Overall time: 67:17min Tool: Milling cutter with 60 inserts (Día. =68cm) InsertRadius inserts Diameter inserts Corner inserts Coolant: Cold air Super-90 oil Dimensional inspection: Initially check the degree &set it for zero using dial gauge. Check width of CP using width gauge. Check the throw using Throw gauge. Maintenance: Preventive maintenance: Every month. Breakdown cause: coolant hydraulic problem, CNC system problem chip conveyor problem etc.  Note:  GFM machine gives the CUTTING PROFILE using which machining process can be understood easily.  If any problem get occurred while machining can understood using CUTTING PROFILE.

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2.2 Operation No 2: Main Bearing Turning                             

Machine name: J & L MACHINE (JONES & LAMSON)-2 Machine type: Flange, SF Gear Hard Turning Operation: Main Bearing (MB) Turning Machining description: Speed: 150 rpm Feed: 100 mm/min Timing: Machining time: 4:35 min Machining time: 33 min Overall time: 37:35 min Tool: V- Tool, RH-TOOL, LH- TOOL Corner change: 240-250 jobs Tool change frequency: 960-1000 jobs Coolant: Super -90 oil Lubricant: Way-68 Dimensional inspection: Check the MB diameter before machining & after machining using DIAL SNAP GAUGE. Check the width of the MB using WIDTH GAUGE. Maintenance: Preventive maintenance: every month Breakdown causes: motor problem, CNC problem, coolant & lubricant oil problems, etc. Note: Feeding is done automatically by CNC system as shown in the Fig.2.1 Tool holder used to hold the V, RH, LH Tool which as operated as per the program given to the CNC system. LH tool machines the left side of MB; RH tool machine the right side of the MB & VTool machines the middle portion of the MB of a crankshaft. Magnetic conveyer system is used to carry out the chip.

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Fig. 2.1: Main Bearing Turning.

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2.3 Operation No 3: Oil Hole Drilling    

Machine Name: WIDMA GUN DRILLING MACHINE (Single spindle) Machine type: CNC Type Operation: Oil Hole Drilling Operation description:

Operation description of oil hole drilling is shown in the table 2.1 Table 2.1: Operation Description. Operation (Diameter in mm) MB oil Hole (7.94mm) CP oil hole (7,94mm)                    

Speed(rpm)

Feed (mm/min)

Time (Min)

Material

Tool change freq. (jobs)

2000

300

3:17min

Carbide

100-125

2000

300

4min

Carbide

100-25

Timing: Machining time of MB Oil Hole: 19:42min Machining time of CP Oil Hole:48min Overall time: 73:42min Tool: Drill cutter: Diameter =7.94mm &length =415mm Bush is used to hold the Drill Coolant system: Coolant: MEHTOL NC14H Automatic cooling system Lubricant oil: Way 68 Maintenance system: Preventive maintenance is dined as per the plan. Breakdown cause: coolant system problems, lubrication problems, electrical & hydraulic problems, etc. Note: Automatic indexing is done to drill CP oil hole as per required angle &position (this is done using CNC Probe) as shown in the fig 2.2. Hydraulic system helps to hold the work piece& in clamping. Magnetic chip conveyor is carrying all chip produced in this operation. Steady is used to support the rotating work piece.

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Fig 2.2: Oil hole drilling.

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2.4 Operation No 4: Counter Boring            

Machine name: RADIAL DRILLING MACHINE Machine type: Manual Drilling Operation: Counter Boring Machine description: Speed:100 rpm Timing: Counter bore tool Tool change frequency:900-1000 jobs Corner change frequency: 240-250 jobs Maintenance: Preventive maintenance as per the plant set. Breakdown causes: Clamping problems, electric motor problems, etc.

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2.5 Operation No 5: Buffing of Oil Holes            

Operation Name: Buffing of Oil Holes Operation Name: Finishing of Oil Countered Oil Holes Tool: Buffer Tool In this operation finishing of counter bored oil holes is done. Emery polish paper attached at end of the tool & polishing is done. Buffer tool is rotated at high speed (about 200rpm) using high pressurized air. It is done by manually. Time: Buffing time of all oil holes: 7-8min Overall time: 7:34-8:34min Maintenance: Only breakdown maintenance.

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2.6 Operation No 6: Induction Hardening                                 

Machine name: EMA INDUCTION HARDENING MACHINE Machine type: CNC Operation: Induction Hardening Purpose: To increase the life of the component Operation description: Initially clean the work piece to remove oil content present on the work. Fit the induction coil of size of CP/MB. Heat the MB/CP to temperature of about half the melting of the material (for given material heat to temperature of 800°𝑐) as shown in the fig.2.3 Hold the job to same temperature or 6-7sec. Then quenching is done in C201POLYMER Oil for 30-32sec only. Maintain the concentration of quenching oil to 12±1 which can be measured by instrument called Refractometer. Timing: Total time to heat all CP &MB:36sec Total quenching time:6min Overall time: 6:36min Induction coil: Voltage: 3*415V Frequency :50 Hz Power :62KVA Temperature :800°𝑐 Quenching system: Quenching oil: C201 polymer oil Maintain the concentration of the oil to 12±1 which can be measured using REFRACTOMETER. Quenching delay ; 30-32sec Maintenance: Preventive maintenance is done as per the plant set. Breakdown causes: electrical problem, induction coil problem. Note: Before heating the work, piece fill the oil holes with wooden plugs. To avoid the + destruction of oil holes. Using this operation life of the component can be increased & hardness can be increased to 55-60%. Check the concentration for every shift by using the refract meter. This provides the fume extractor which extracts all fumes produced while heating & quenching process.

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Fig.2.3: Induction Hardening.

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2.7 Operation No 7: Furnacing                         

Operation name: Furnacing (Tempering) Purpose: To relieve residual stresses. To reduce bending occurred in the in-induction hardening operation. To increase the life of the component. Tempering description: Furnace temperature: 370°c Duration of temperature: 8 hours Using fans air is circulated. Timing: Tempering time: 8 hours Overall time: 8 hours Furnace details: Capacity furnace: 12 work pieces Fans provided at the top of the furnace for air circulation which are run by electric motors. Coils are present at the sides of furnace using which heating has been done. Maintenance: Preventive maintenance is done as per the plan set. Breakdown causes: electrical problems, furnace problems, etc. Note: Using this process, the stresses are get relieved and life of the component also increases. The loading of the crank shafts in the furnace is shown in the fig.2.4 By the tempering process the hardness can increased by 45-50% only. Temperature of the furnace is maintained by controlling the voltage and current through resistance coils. Tempering is also known as the air quenching process. After the operation check bend using dial gauge.

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Fig. 2.4: Furnacing.

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2.8 Operation No 8: Shot Blasting                    

Operation name: Shot Blasting Machine name: SAND STORM MACHINE Purpose: To remove scales developed on surface of component. Shot blasting Description: Speed of work piece is about 35 to 40 rpm. Pressure of the steel balls hitting the component is about to be 90kg/cm².The shot blasting chamber is shown in the fig. 2.5 This hitting of steel balls is done for 15 to 20 minutes till the scale, dust etc are completely removed from the work piece. Timing: Shot blasting time: 20min Overall operation time: 23:46 min Maintenance: Preventive maintenance is necessary to check only working blower and pressure of the steel balls. Breakdown maintenance causes: electric motor problem, nozzle problems, etc. Precautions: Steel balls used should the diameter less than 2 to 3mm. Pressure should maintain to required level. After every 5 to 10 minutes check work surface (because due to high pressure balls the surface of work and damage). Check the leakages in pipes for every operation. For every shift check nozzle hole (if necessary).

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Fig.2.5: Shot blasting.

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2.9 Operation No 9: MB Rough Grinding                               

Operation name: MB rough grinding Machine name: MSO GRINDING MACHINE Operation description: Speed of the grinder: 700 rpm Speed of the work piece :25 - 30rpm Feed: manually Cutting speed: 0.22m/min Tool: Material: ceramics Grinder diameter: Dresser used to sharpen the grinder Time: Machining time: Overall time: Coolant oil: Coolant oil:WS600(soap oil) Temperature of coolant oil: 18-20°c Check the oil concentration for every shift (i.e. to be about 12±1) Lubricant oil: Lube oil: Way-68 Dimensional inspection: Check the MB diameter by the dial snap gauge. Check width of the MB by width gauge. Check MB thrust radius by radius template. Check for the crack by crack test method. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, feeding problem, etc. Note: Initially check bend in work using dial gauge. Before loading the work piece on machine apply grease at both end of work to avoid friction.  As the feeding is manual check the diameter of MB at every time using dial snap gauge.  Before start of machining control, the radius at the corner of the grinder using MSO dresser radius at corner should be as per the standard provided.

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2.10 Operation No 10: CP Rough Grinding                                   

Operation name: CP rough grinding Machine name: TOSS GRINDING MACHINE Machine type: CNC Operation description: Speed of the grinder: 650 rpm Speed of the work piece: 25-30rpm Cutting speed: 30-32mm/min Indexing required in this operation is done automatically by CNC system Tool: Grinder diameter: 1000mm Material: ceramics Diamond dresser used to sharpen the grinder Time: Machining time: 46:24min Overall time: 50:24min Job/shift:7 Coolant oil: Coolant oil: WS600(soap oil). Temperature of coolant oil: 18-20°c. Check the oil concentration for every shift. Coolant flow rate: 80-90lpm. Lubricant oil: Lube oil: Way-68 Dimension inspections: Check the CP diameter by dial snap gauge. Check width of CP by width gauge. Check CP thrust radius by radius template. Check the throw using throw gauge. Check for the crack by crack test method. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, feeding problem etc. Note: As per feeding is manual check the diameter of CP at every time using dial snap gauge. Before start of the machining control the radius at the grinder of the grinder. the process is shown in the fig. 2.6

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Fig. 2.6: CP Rough Grinding.

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2.11 Operation No 11: FE & GE Turning & Groove Cutting   

Operation name: FE & GE Turning & Groove Cutting Machine name: J & L MACHINE (JONES &LAMPSON MACHINE)-01 Machine type: CNC

The operation description of FE & GE turning & groove cutting is shown in table 2.2 Table 2.2: Operation description. Operation

Speed(rpm)

FE turning GE turning Groove cutting

700 700 700

Feed (mm/min) 2 2 2

Time (min)

Tool

6:34 5:39 11:22

LH/RH LH/RH V-Tool

                       

Timing: Machining time: 22:75 min Overall time: 28:75 min Job/shift :7-8 Tool: Left hand, right hand tool, V-tool Material: HSS Using V tool, the groove cutting is done Coolant oil: Coolant oil: WS600(soap oil) Temperature of coolant :18-20°c Check the oil concentration for every shift (i.e.to be about 12± 2) Coolant flow rate:80-90lpm Lubricant Oil: Lube oil: Way-68 Dimensional inspection: Check the GE & PE diameter by Dial snap gauge. Check big collar thickness using snap gauge (Go /NOGO gauge). Check for the crack by crack test method. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, probing problems. Note: With the help PROBE system location of the groove & ZERO setting distance is set in the CNC system.  Diameter of the GROOVE can check by using C-Gauge.  The cutting speed is on this machine is about to be 106.78mm/min.

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2.12 Operation No 12: MB Finish Grinding                                 

Operation name: MB Finish Grinding Machine name: AMC-CNC-1 MACHINE Machine type: CNC Operation description: Speed of the grinder: 800rpm Speed of the work piece: 25-30 rpm Use steady to support the work while machining. Before machining initially check the diameter of MB & set the program. Tool: Grinder diameter: 1000mm Material: ceramics Diamond dresser used to sharpen the grinder (done automatically). Time: Machining time: 30:12min Overall time: 34:46 min Job/shift:10 Coolant oil: Coolant oil: Bio cool oil Temperature of coolant oil: 18 -20°c Check the oil concentration for every shift (i.e.to be about 12±1) Coolant flow rate: 80 – 100 LPM Lubricant oil: Lube oil: Way -68 Dimensional inspection: Check the MB diameter by dial snap gauge (refer it with std specimen). Check width of MB by width gauge. Check CP thrust by radius template. Check the finishing using the appropriate method. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, feeding problem, etc. Note: To this machine a Marposs calliper is provided using which the diameter of the MB is checked while machining.  Before start of machining control, the radius at the corner of the grinder using diamond dresser (radius at the corner should be as per std. provided). The machining operation is shown in the fig.2.7  The STD master used should kept in coolant to control its diamonds.

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Fig. 2.7: MB Finish Grinding.

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2.13 Operation No 13: CP Finish Grinding   

Operation name: CP finish grinding Machine name: LANDIS GRINDING MACHINE Machine type: CNC

Operation description:                             

Speed of the grinder:550 rpm Speed of the work piece :25-30 rpm Feed: manually Indexing required in this operation which is done automatically by CNC system. Tool: Grinder diameter :1000mm Material: ceramics Diamond dresser used to sharpen the grinder. Time: Machining time: 67:11min Overall time: 70:11min Job/shift:6 Coolant oil: Coolant oil: WS600(soap oil) Temperature of coolant oil: 18-20°c Check the oil concentration for every shift (i.e. to be about 12±1). Coolant flow rate: 90-100lpm Lubricant oil: Lube oil: Way -68 Dimensional inspection: Check the CP diameter by dial snap gauge. Check width of CP by width gauge. Check CP thrust radius by radius template. Check the finishing of component using appropriate method. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, feeding problem, etc. Note: As the feeding is manual check the diameter of CP at every time using dial snap gauge & for clamping the work hydraulic system is used.  Before start of machining control, the radius at the corner of the grinder & sharpen the grinder using dresser (radius at corner should be as per the STD provided).

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2.14 Operation 14: Pad Milling & Hole Drilling on Pad   

Operation name: Pad Milling & Hole Drilling on Pad Machine name: MILLING & DRILLING MACHINE Machine type: CNC

The operation of pad milling and hole drilling shown in table 2.3 Table 2.3: for both pad milling & hole drilling on pad. Operation

Speed (RPM)

Pad milling

250

Feed Time(min) (automatic For by CNC) (whole job) 50mm/min 6:18

Centering

250

50mm/min

4:8

Drilling (2 holes on each pad) Counter boring

300

50mm/min

6:30

300

50mm/min

7:49

Tapping (rolled type)

300

-

9:46

                 

Tool

Material of the tool

Milling cutter

Carbide alloy HSS

Drill of diameter =12.5mm Drill(diameter=14.7mm)

Combination tool(D1=16.67) (D2=23mm) Tapping tool (M14.7*1.4)

HSS

Carbide

-

Tool: Total milling time: 6:18 min Total drilling time: 26:36min Overall operation: 39:39min Coolant: Coolant oil: bio cool -100 Check the coolant oil level for every shift & ensure its concentration is as per the std provided. Lubrication system: Lube oil: Way68 Check the lube level for every shift. Dimensional inspection: Check the width of the pad. Check the holes drilled using plug gauges. Check the thread using thread plug gauge. Using receiving gauge check hole positions. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, CNC problem, lubrication system problems etc.

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2.15 Operation No 15: End Drilling & Tapping    

Operation name: End drilling & Tapping Machine name: PRIDE DRILLING MACHINE Machine type: CNC Drilling Machine Flange end drilling: No. of holes =12 & one dowel hole.

The operation description of end drilling and tapping in flange end shown in the table2.4 Table 2.4: For end drilling and Tapping.



Operation

Speed (RPM) 1250

Feed (automatic by CNC) 10mm/min

Time (min)for (whole job) 2.14

Drilling Drilling (D=17.5mm) Tapping

1250

10mm/min

1.96

250

10mm/min

5.32

Drilling dowel hole Reaming

2000

10mm/min

0.4

1250

10mm/min

0.7

Chamfering

1000

-

0.76

Tool (specification)

Material of the tool

Drill (dia. =19.18mm) Drill (dia.=17.5mm) Tapping tool(M17.5*1.6) Dowel tool(D=5.95mm) Reaming tool (6.32mm) Chamfering tool (7.10°*90°)

Carbide alloy Carbide Carbide Carbide HSS Carbide

Gear end drilling: No. Of holes =8 & one dowel hole.

The operational description of end drilling and tapping in gear end shown in table2.5 Table 2.5: For end drilling & tapping. Operation

Speed (RPM) 1250

Feed (automatic by CNC ) 10mm/min

Time (min for (whole job) 3.5

Drilling Drilling (d=18.26mm) Tapping

1250

10mm/min

4.06

250

10mm/min

5.32

Drilling dowel hole Reaming

2000

10mm/min

0.26

1250

10mm/min

1.12

Chamfering

1000

-

0.70

Tool (specification)

Material of the tool

Drill (dia =17.5mm) Drill (dia =18.26mm) Tapping tool (M18.26*16) Dowel tool (D=5.95mm) Reaming tool (6.32mm) Chamfering tool(7.10°*90°)

Carbide alloy Carbide Carbide Carbide HSS Carbide

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ASHOK IRON WORKS PVT LTD.                  

Total time: For FLANGE end drilling: 26:11min For GEAR end drilling: 36:40min Overall operation time: 65:51min Coolant system: Coolant oil: bio cool – 100 oil Check the level of the coolant for every shift Lubrication system: Lube oil: Way 68 Check the level of lube oil for every day Dimensional inspection: Check the hole positions using receiving gauge. Check the diameter of the drilled holes using the plug gauges. Check the thread using thread plug gauge. Check the depth of holes different diameters using Venire. Maintenance: Preventive maintenance is done as per plan set. Breakdown causes: coolant oil problem, electric problem, CNC problem, lubrication system problem etc.  Note:  Drilling at both ends is done to do coupling (it joins the 2 rotating shafts).  The tapping (internal threading) done is the rolled type tapping.  Clamping of work piece is by manually.

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2.16 Operation No 16: Keyway Milling                         

Operation Name: Keyway Milling Machine name: JOYTI KEYWAY MILLING MACHINE Machine Type: Manual Machining description: Key way is done at both ends of crankshaft Key way type: WOODRUFF keyway Work piece is Stationary Speed of the Milling Cutter:180RPM Feed: Manual Tool: Milling cutter Material: HSS (High Speed Steel) Time: Time required at FE End:9.47min Time required at GE End:10.23min Overall operation time:20.10min Coolant System: Coolant oil: WS600 Check the level of the coolant for every shift. Dimensional Inspection: Check the width of key slot using Width gauge. Check the depth of the slot. Maintenance: Preventive Maintenance is done as per plan set. Breakdown causes: Coolant oil problem, lubrication system problem clamping problems, etc.  Note:  Key is used to connect two pieces in such a way that there is no relative motion between them. The key way milling machine is shown in the fig.2.8  Special milling cutter is used to produce woodruff keyway.  Indexing done for proper positioning of the key, this is done manually.

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Fig. 2.8: Key way milling.

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2.17 Operation No 17: Belt Lapping                   

Operation Name: Belt Lapping Machine Name: BOMBAY LATHE Machine type: Manual Purpose: Polishing of component Maintaining of diameter of MB, CP, FE, GE at all positions Operation Description: Speed of the work: 200rpm Using polish paper, the polishing is done manually. Using snap dial gauge diameter is checked every time. Time: Total polishing time: 3min Maintenance: Preventive maintenance is as per control plan. Breakdown causes: Lubrication system problems, Work clamping problems, etc. Note: Using polish paper polishes the surface of the component. Snap dial gauge is used to inspect the dia. of the component. No Cooling system is required.

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2.18 Operation No 18: CNC Lapping         

                    

Operation Name: CNC Lapping Machine name: CNC LAPPING MACHINE Machine type: CNC Purpose: For Super Finishing Operation Description: In this operation super finishing of all CP & MB, Big collar is done. The CNC lapping machine is shown in fig.2.9 Indexing required for CP finishing is done automatically by CNC system. For finishing thrust the reciprocating motion given to work using motor attached at head end (reciprocating displacement should be limited up to 3.5-4mm only, which measured by using Dial gauge). Initially work is clamped at correct position using stand provided at middle of machine It consists total 7 arms, in that 3 arms for rough & 3 arms for complete super finish & remaining one arm is finishing the big collar. Then after finishing the operation measure Diameters of CP, MB, Collar using the Micrometre& also checks finishing by appropriate method. Operation Time: Total time required to complete 1 job: 33.26min Jobs/shifts: 8-9 Polish Paper: Norton Lapping film Coolant system: Coolant oil: ECOCUT HFN-5 oil Check the level of coolant for every day. Lubrication system: Lube oil: Way 68 Check the level of lube oil for every shift. Maintenance: Preventive maintenance is done as per the control plan (usually observation done for every day & maintenance done for each month). Breakdown causes: Coolant, Lubrication system problems, electric problems, CNC problems, etc. Note: Hydraulic system is used to clamp the work (Hydraulic oil used WAY46). In this machine the 40-micron Norton film is used for rough finish & 20-micron Norton film used for full finish for CP & MB & for finishing the Collar 30-micron film is used. Check finishing after this.

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Fig. 2.9: CNC lapping machine

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2.19 Operation No 19: Loading & Balancing           

       

Operation Name: Loading and Balancing Machine Name: ABRO BALANCING MACHINE Purpose: Loading is done attaching counter weights to balance the crankshaft. Operation Description: Loading: In loading operation each 6kg counter weights are attached on pad by Nut & Bolt arrangement. Separate machine is not required for loading. Balancing: Balancing is done on ABRO Balancing machine. In this operation work is made to rotate at speed of 300rpm & using probe sensor attached to work the unbalancing observed on display in different planes (ABRO Software is used to analysis the unbalancing in different planes). This soft's shows unbalancing plane & it is locating on in terms of angle. Then by manual indexing for required angle is done. If the extra material is present then it is removed by drilling the holes on counter weights at indexed position. (for drilling feeding done manually). If the negative unbalance becomes then the counter weights are replaced by new one & then again balance test is done. Note: In loading counter weights assembly dowel ring used to fit counter wt. in crankshaft pad holes. In ABRO Balancing probe sensor is connected to work at head only. The ABRO software shows the positive unbalancing in terms of weight and in terms of diameter, depth of hole to be drilled on pad at appropriate positions.

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2.20 Operation No 20: Writing Job No. & Finish Cleaning  Operation Name: Writing Job no & finish cleaning  Operation description:  After balancing the crankshaft, the job number & counter weight No. are written on the crankshaft is using MARKING MACHINE.  Then verify the job number written at flange & no’s written on counter weights.  Then check the oil holes using small steel balls passing through the holes.  Then final inspection is done & check the dust level in oil holes using appropriate test.  Clean work by plastic paper to remove oil content left on work after lapping operation.  Then spray the VCR-412 oil on work with some high pressure.  Then cover it with plastic paper & pack it to iron boxes.  Then keep ready for EXPORT (Exported to TATA CUMMINS IND LTD). TOTAL CYCLE TIME FOR THE MACHINING OF CRANKSHAFT (KV-12): 17 hours (approx.)

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CHAPTER 3 QUALITY DEPARTMENT Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places on emphasis on three aspects. 1. Elements such as controls, job management, defined and well managed processes performances & integrity criteria, & identification of records 2. Competence, such as knowledge, skills, experience, & qualifications 3. Soft elements, such as personnel, integrity, confidence, organizational, motivational, team spirit & quality relationships. Controls include product inspection where every product is examined visually, & often using different instruments a fine detail before the product is sold into the external market. Inspectors will be provided with lists & descriptions of unacceptable product inspection such as cracks, surface or blemishes for example. The quality of outputs is at risk if any of these three aspects is deficient in any way. Quality control emphasizes testing of products to uncover defects & reporting to management who make the decisions to allow or deny product release, whereas quality assurance attempts to improve & stabilize production to avoid or at least minimize, issues which led to the defect in first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing the contract.

 Functions: 

Receiving inspection: When the job imported from outside companies the receiving inspection should be done to check dimensions & specification are as per the required & as per the imported company  In receiving inspection:  All dimensions of the job should be inspected Ex. Length, diameters width  Check material properties of the job Ex. Hardness  Check for the cracks, defects in components  In process inspection: In process inspection of the job is done after different operations Ex. Linear check is done after turning of GE & FE of crankshaft. There are different inspections done for crankshaft while machining.

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1. Linear check-01 after operation no.6: This inspection is done after the induction hardening operation of the crankshaft. In this inspection the linear dimensions are checked & bend occurred due to IH operation measured. a) Check the linear dimensions of the job b) Check the bend by using dial gauge If any mismatching of dimensions work with std. control plan then report Will be sent to upper level dept & corrective actions are taken.

2. Linear check-02 after operation no.8: This inspection is done same as linear check. If any mismatching of dimensions work with std. control plan then report will be sent to upper level dept & corrective actions are taken.

3. Crack test after operation no.14: Work piece is checked for cracks that occur during the machining process. Machine name: MAGNIFIED CRACK TEST MACHINE.

 Procedure: 1. Clean the work piece completely & then wash it with mixture of kerosene oil & magnified powder. 2. Work piece is subjected to shocks around 7-8 times & the work piece is electrically magnetized. 3. UV rays are radiated on the work piece 4. Thus the cracks (FR or MR) are observed 5. If FR cracks are seen then it is concluded that the cracks have occurred during the forging process, it is reported to the company from which the work piece is imported. 6. If MR cracks are observed then they are the ones that occurred during machining & the corrective measures are taken.

4. Inspection after operation no.17: All linear dimensions are checked & compared with standards & the finishing of the work piece is checked.

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 Final inspection: 1. Work piece is taken to the standard room & is cleaned neatly 2. Diameters of all CP, MB, GF, FE, COLLAR, GROOVES electric gauges & compared with standards. 3. Position of all holes are checked using receiving gauges. 4. Check the width, oil hole diameters, GE &FE end hole diameters & it is also checked for Threading using respective gauges. 5. Check the hardness of jobs. 6. Check the dust present in the oil holes using the appropriate methods. 7. If the dimensions of the work piece don’t match with the standards then corrective measures are taken.

 Ferro test: In this test all dimensions of the work piece including the dimensions that cannot be checked manually; hence they are checked using CMM (coordinate measuring machine).

 Process audit: The inspectional results of a work piece are cross checked with the results of the standard work piece. It is done during the in-process inspection.

 Dock audit: The inspectional results of a work piece are cross checks with the results of the standard work piece. It is done during final inspection.

 Calibration: In calibration the measurements used for the dimensional analysis are calibrated every time to reduce the errors that can occur during the measuring. If an instrument giving the high error then it is replaced by another with low error instrument. Some standards are followed while calibration that depends on the companies.

 Corrective action: When the dimensions of the work piece are not matched with the std work sheet some corrective actions are taken.

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 Inspection Parameters: The inspection parameters of the crankshaft is shown in the Table 3.1 Table 3.1: Inspection Parameters. Sl. No.

Diameter

1 2 3 4 5 6 7

Damper Diameter GE Oil Seal Diameter GE Gear Mounting Diameter Main Journal Diameter Pin Diameter FE Gear Mounting Diameter FE Oil Seal Diameter

Lower Master Value in Inches 4.3599 4.3740 4.3800 6.4984 4.2484 7.2580 7.2479

Higher Master Value in Inches 4.3611 4.3751 4.3810 6.5002 4.2500 7.2601 7.2502

 Gauges used for Inspection:  Micrometre: Using the Micrometre check the width of the various parts like Main Bearing, Crank pin, Key slots the micrometre is shown in the Fig.3.1

Fig.3.1: Micrometre

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ASHOK IRON WORKS PVT LTD.  Plug Gauge: The plug is used to checking the drilled oil holes in the crankshaft shown in the fig.3.2

Fig.3.2: Plug gauge  Throw gauge: Check the throw using the throw gauge shown in the fig.3.3 this gauge is used in checking the throw of the main bearing and connecting pin.

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Chapter 4 ROLE OF STUDENT DURING INTERNSHIP During the internship period in Ashok Iron Works ltd, The Machining and Assembly division, I undergone many operations (Milling, Drilling, Roughing, Grinding, furnacing, Hole drilling etc.) on the crankshafts. I Observed different types of crankshafts (KV12, KV16, V28) machined in respective machines. Got to know different types of tools specification in different operations, finally final inspection is done and product has been dispatched.

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CHAPTER 5 CONCLUSION In review this internship has been an excellent and rewarding experience. I have been able to meet and network with so many people that I am sure will be able to help me with opportunities in the future. As an engineering student it is important to know the industrial ( machining operations) working environment. These types of visit help us to know about industry work ethics, problems faced, dedication required. I learnt how the management works, workers skills, knowledge required for testing processes carried out in the Maching and Assembly Division.Beacause of this exposure, further we will concentrate on studies by industrial perspectice; so that I can be ready to face the challenges and solve the problems in any area after completing engineering.

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