CASE STUDY
There are two products:
1. Impeller
2. Cylinder sleeve.
[Link]:
An impeller is a rotating component of a centrifugal pump which transfers energy from the motor that
drives the pump to the fluid being pumped by accelerating the fluid outwards from the center of
rotation.
Flow Diagram- Manufacturing process:
a) Sand casting:
In sand casting which is also known as sand molded casting, an object is produced by
sand mold. The process involves pouring of the molten metal in to the mold cavity. The molten metal
is then cooled to the room temperature. The metal is solidified. After cooling, the metal object is
separated from the mold.
b) Riser cutting:
A riser is a ceramic form built into a mold to act as a "reservoir" for molten metal; it
feeds metal to the mold and thus compensates for any shrinkage of the casting during solidification.
After cooling, the riser is removed before the casting is unmolded.
c) Shot blasting:
Shot Blasting is a process which is used to clean, strengthen and polish metals. It is
one of the processes of Abrasive blasting. Also most of the abrasive blasting is shot blasting (with
metal shots) and sand blasting (with sand) only. This blasting operation refers to the operation of
forcibly propelling a high-pressure stream of abrasive material against a surface in order to:
Smooth a rough surface
Roughen a smooth surface
Shape a surface
Remove surface contaminants
d) Impeller machining Process on 5-Axis Machining Centre-CNC:
Roughing Tool Path
Blade Finishing Tool Path
Hub Finishing Tool Path
HUB Finishing
e) Key way machining:
A key is a machine element used to connect a rotating element to a shaft. Once
installed, the key prevents rotation between the two parts to enable torque transmission.
Broaching is a machining process that uses a toothed tool, called a broach, to remove
material. With our linear broaching capabilities, the broach is run linearly against the surface
of the workpiece to effect the cut. In the broaching process, the cut is performed in one pass
of the broaching tool, which makes it very efficient.
[Link] SLEEVE
Cylinder sleeves, also called "cylinder liners," are cylindrical parts that are contained inside the
cylinder block. These cylinders are a critical component in the engine, as they form the container in
which the pistons slide up and down at high speeds.
Sand casting comes with many problems, including an extremely hot and dirty work environment.
The Spin cast method did away with these problems and contributed to a dramatic improvement in
working conditions surrounding cylinder sleeve production as well as a significant reduction in
environmental impact.
Fine Boring
Boring is the process which gives the final
look of inner diameter. We perform boring
operation on vertical machining Centre which
is fully computerized control machine. We
also use special purpose boring
machine. Which maintains dimension accuracy, taper, ovality and surface finish.
Outer Diameter CNC Turning
In turning we perform outer diameter of
liner on CNC machine, which is
computerized control machine, gives high
accuracy in dimensional parameters,
surface roughness parameters and
geometrical
parameters. A main benefit of OD CNC Turing is to minimize cycle time, repeatability of
quality and consistency product.
Grinding & Stage Inspection
Grinding is the process where super surface
finish can be maintained on products. We have
two type of grinding process Centre less
grinding and cylindrical grinding.
Grinding controls
dimensional parameters, surface parameters and geometrical parameters. The process indicators like
Cp/Cpk is maintained in this process.
Plauto Honing
Honing is the process where required hex pattern
can be maintained in finish inner diameter. We
use Plato honing process. The main benefits of
Plato honing process is to achieve required
quality parameters like surface finish Ra, Rt,
Rmax, R3z, Rp, MR1,MR2 etc. with
process control indicators like Cp/Cpk