12BME1107-ABOUT THE COMPANY

24
1 ABOUT THE COMPANY RICO is a world- class engineering group supplying a wide range of high precision fully machined aluminum and ferrous components and assemblies to automotive OEMs across the globe. RICO’s integrate services include design, tooling, casting, machining, assembly and R&D across ferrous and aluminum products. RICO GROUP OF INDUSTRIES TABLE 1.1 COMPANY NAME PARTNERSHIP PRODUCTS FCC RICO 50% FCC & 50% RICO Clutch assembly two wheelers and four wheelers CONTINENTAL RICO 50% CONTINENTAL & 50% RICO Hydraulic Brake products and services MAGNA Powertrain RICO 50% MAGNA Powertrain & 50% RICO Oil pump and Water pump RICO JINFEI 92.5% RICO & 7.5% JINFEI Aluminum Alloy Wheels- Two Wheelers RICO USA& UK 100% RICO Assembly, logistics, Customer support TABLE 1.2. RICO IN INDIA COMPANY NAME LOCATION PRODUCTS/PROCESSES DHARUHERA Dharuhera Aluminum Casting and Machining RICO GURGAON Gurgaon Aluminum /Ferrous Dies & Moulds, R&D, CAD/CAM CAE RICO HARIDWAR Haridwar Aluminum Casting & Machining RICO BHIWADI-1 Bhiwadi Machining RCL LUDHIANA Ludhiana Ferrous Casting & Machining RCL MANESAR Manesar Aluminum Casting & Machining FCC RICO Manesar Manesar Clutch Assembly FCC RICO Pune +RICO Pune Pune Machining CONTINENTAL RICO Gurgaon Hydraulic Brakes MAGNA RICO Dharuhera Oil and Water Pump RICO JINFEI Manesar Aluminum Alloy Wheels RICO Chennai Chennai Aluminum Casting and Machining

Transcript of 12BME1107-ABOUT THE COMPANY

Page 1: 12BME1107-ABOUT THE COMPANY

1

ABOUT THE COMPANY

RICO is a world- class engineering group supplying a wide range of high precision fully

machined aluminum and ferrous components and assemblies to automotive OEMs across the

globe. RICO’s integrate services include design, tooling, casting, machining, assembly and R&D

across ferrous and aluminum products.

RICO GROUP OF INDUSTRIES

TABLE 1.1

COMPANY NAME PARTNERSHIP PRODUCTS

FCC RICO 50% FCC & 50% RICO Clutch assembly –two

wheelers and four wheelers

CONTINENTAL RICO 50% CONTINENTAL &

50% RICO

Hydraulic Brake products and

services

MAGNA Powertrain RICO 50% MAGNA Powertrain &

50% RICO

Oil pump and Water pump

RICO JINFEI 92.5% RICO & 7.5% JINFEI Aluminum Alloy Wheels-

Two Wheelers

RICO USA& UK 100% RICO Assembly, logistics,

Customer support

TABLE 1.2. RICO IN INDIA

COMPANY NAME LOCATION PRODUCTS/PROCESSES

DHARUHERA Dharuhera Aluminum Casting and

Machining

RICO GURGAON Gurgaon Aluminum /Ferrous Dies &

Moulds, R&D, CAD/CAM

CAE

RICO HARIDWAR Haridwar Aluminum Casting &

Machining

RICO BHIWADI-1 Bhiwadi Machining

RCL LUDHIANA Ludhiana Ferrous Casting & Machining

RCL MANESAR Manesar Aluminum Casting &

Machining

FCC RICO Manesar Manesar Clutch Assembly

FCC RICO Pune +RICO

Pune

Pune Machining

CONTINENTAL RICO Gurgaon Hydraulic Brakes

MAGNA RICO Dharuhera Oil and Water Pump

RICO JINFEI Manesar Aluminum Alloy Wheels

RICO Chennai Chennai Aluminum Casting and

Machining

Page 2: 12BME1107-ABOUT THE COMPANY

2

RICO AUTO INDUSTRIES –DHARUHERA

LOCATION:-

69 K.M STONE, DELHI- JAIPUR HIGHWAY,

DHARUHERA(H.R)

CERTIFICATION:

ISO9000-1994

QS-1998

ISO 1401-2002

OHSAS 18001-2002

CAPACITY :

Over 16 million high pressure die cast components are produced per annum.

FUTURE PLANS OF THE FIRM :

Reduce dependency on other industrial sector.

Searching for new customers

Expansion of the firm.

Investment in the other profitable industrial sectors.

PRODUCTS AT RICO DHARUHERA

Table 1.3

PRODUCTS CUSTOMER

Clutch Assembly(2 Wheeler) Hero-Moto Corp

Wheel Hub Assembly(2 Wheeler) Hero-Moto Corp

Brake Panel Assembly(2 Wheeler) Hero-Moto Corp

CUSTOMERS:-

Hero Moto Corp

Maruti Suzuki

Ford Motor Company

Volvo

Cummins

Page 3: 12BME1107-ABOUT THE COMPANY

3

5-S OF THE COMPANY :

SEIRI (SORTING)

SEITON (SYSTEMATISING)

SEISO (SHINING)

SEIKETSU (STANDARISATION)

SHITSAKE(SELF DISCIPLINE)

UTILITY :-

Maintenance department is responsible for the management and supply of electricity and

compressed air to different section of firm.

Power comes from HVPNL (HARYANA VIDYUT PARISHADH NIGAM LTD.) 1,30,000

Kw-h / day

Generated voltage – 11 KV

Compressor : 2200 CFM

Screw type compressor used.

Fig 1.

RICO DIES PRODUCTION SHOP :

RICO dies unit molds (machines) the dies required in the HPDC Shop.

It involves manufacturing of new dies and maintenance of old once.

Page 4: 12BME1107-ABOUT THE COMPANY

4

CAD/CAM DIVISION :

Function of this unit is product design, tool design, jig design, etc.

AUTOCAD software was used by the department for 2D layouts

Pro E and CATIA were used for 3D Design and Modelling

CNC Machines were coded through LAN system. Code is generated on CAM and uploaded in

CNC Machines through LAN system.

Fig 2. RICO Dharuhera

Page 5: 12BME1107-ABOUT THE COMPANY

5

MASTER PRODUCTION CHART :-

FLOW CHART 1.

RAW MATERIAL:-

ADC-12 & ADC-14 alloys

FURNANCE (MELTING):-

Electric Arc Furnace is used to melt the raw aluminum into liquid metal

An electric arc furnace (EAF) is a furnace that heats charged material by means of

an electric arc.

Alloys are melted in a furnace at 1000°C.

Raw Aluminum is brought to the furnace on conveyor belts.

When the Aluminum enters the red hot furnace maintained at 1000°C aluminum melts

This liquid Aluminum passed to molding machines through channels (pipes) which pour

the molten metal into a reservoir.

Each injection molding have a separate reservoir.

RAW MATERIAL STORAGE

FURNANCE (MELTING)

HIGH PRESSURE DIE CASTING

HEAT TREATMENT

MACHINING ROW (TURNING, DRILLING , etc.)

QUALITY UNIT

PAINT SHOPPACKAGING AND

STORAGE

Page 6: 12BME1107-ABOUT THE COMPANY

6

Fig 3. Electric arc furnace

FOUNDARY SHOP

HIGH PRESSURE DIE CASTING:-

Here, the liquid metal is injected with high speed and high pressure into the metal

mold.

The basic equipment consists of two vertical platens.

The bolsters are placed on these platens and this holds the die halves.

Out of the two platens, one is fixed and the other movable. This helps the die to open

and close.

A specific amount of metal is poured into the shot sleeve and afterwards introduced

into the mold cavity. This is done using a hydraulically-driven piston.

After the metal has solidified, the die is opened and the casting eventually removed.

Fig 4. High Pressure Die Casting

Page 7: 12BME1107-ABOUT THE COMPANY

7

TYPES OF HIGH PRESSURE DIE CASTING PROCESS

Hot Chamber Process

Cold Chamber Process

Hot Chamber Process:-

The hot-chamber process is applicable only for zinc and other low melting

point alloys that does not affect and erode metal pots cylinders and plungers.

The molten metal for casting is placed in the holding furnace at the required

temperature adjacent to (sometimes as part of the machine itself) the machine.

The injection mechanism is placed within the holding furnace and most of its

part is in constant touch with the molten metal. When pressure is transmitted

by the injection piston, the metal is forced through the gooseneck into the die.

On the return stroke, the metal is drawn towards the gooseneck for the next

shot.

This process ensures minimum contact between air and the metal to be

injected. The tendency for entrainment of air in the metal during injection is

also minimized.

Fig. 5 Hot Chamber Die Casting

Cold Chamber Die Casting:-

The injection system is not submerged in molten metal.

Metal gets transferred by ladle, manually or automatically, to

the shot sleeve.

Page 8: 12BME1107-ABOUT THE COMPANY

8

The metal is pushed into the die by a hydraulically operated

plunger. This process minimizes the contact time between the

injector components and the molten metal.

The entrainment of air into the metal generally associated with

high-speed injection can cause gas porosity in the castings. In

the cold chamber machine, injection pressures over 10,000 psi

or 70,000 KPa is obtainable.

Fig 6 Cold Chamber Die Casting

RICO DIE CASTING (HPDC UNIT) :-

18 high pressure die casting machines in the HPDC SHOP

In HPDC machine two dies are used :

Fixed die ( cover die)

Movable die (ejector pins)

These machines have different locking force like 660 ton, 560 T, 400 T, 250 T, 200 T,

160 T, 135 T.

Dycote is used for cooling of the die.

The die is also cooled by water for efficient cooling of the casting. This increase dies life.

HPDC machine is controlled by three factors :

Accumulator pressure

Nitrogen pressure

Die opening time

Nitrogen pressure is produced with the help of nitrogen gas.

Page 9: 12BME1107-ABOUT THE COMPANY

9

Nitrogen gas pushes the piston accumulator and thus accumulator pressure is produced.

The time between closing the die for casting to the opening it, is called die opening time.

PROCESS:-

Spray the mold with lubricant and close it. This helps to maintain the inside temp. Of

the die and also allows easy removal of cast product.

The nitrogen gas increases the accumulator pressure and the molten metal is injected

into the shot sleeve.

The metal is injected at very high pressure which ensures the precise shape of cast

object.

After the mold fills completely, it is allowed to cool under high pressure.

Open the die and cast product is removed with the help of ejector pins.

COMPONENTS MADE IN HPDC SHOP :-

Outer clutch

Centre clutch

Friction disc

Lifter plate

Pressure plate

Front & rear hub

Front & rear brake panel

TYPES OF COOLING IN HPDC SHOP :-

SPOT COOLING: The cooling is done at particular spots only.

LINE COOLING: Continuous cooling is done. An entire region is cooled by this.

FUNCTION OF DYCOTE :-

( Filler + bonding agent + water )

The principal functions required of a coating for die casting are:

Control of the metal flow to ensure that it reaches all parts of the die at a

sufficient temperature to prevent the formation of seams, cold laps, etc.

Control of heat transfer to obtain better solidification and ensure that the castings

are properly fed.

Good surfaces, and therefore a reduction in finishing costs

Longer die life, therefore increased productivity and reduced maintenance and

cost.

Page 10: 12BME1107-ABOUT THE COMPANY

10

FACT :-

The layer of DYCOTE with a coarse surface, the contact between molten metal and

DYCOTE is significantly reduced, because the metal, due to its surface tension, is first

in contact with only the “peaks “of the layer, and only after a time, though this is

extremely short, does it penetrate into the "valleys", after which the air escapes through

the channels in the permeable coating. The result of this phenomenon is to reduce heat

loss to a minimum in the molten metal, which thus maintains its fluidity at the critical

moment to fill the die completely.

SELECTION OF DYCOTE COATING :

The section thickness of the casting. One of the main properties of a coating is its ability

to aid the filling of the die. When the casting concerned has a thin section then a coarse

DYCOTE with high insulation properties should be considered.

The surface finish requirement of a casting is very important but coatings which give

very good surface finish make it more difficult to fill the die because of the smooth

surface of the coating and because the insulation is not as good as with a coarser

coating. The balance of surface finish and insulation will therefore be a compromise.

FETTLING PROCESS :

First take O.K casting and start fettling.

Remove all outer flake.

After that face of parting line is cleaned with the help of rough file.

Clean of flake of ejection pin.

Clean slot hole.

After that check the casting and put it in trolley.

Page 11: 12BME1107-ABOUT THE COMPANY

11

Fig.7 Component after Fettling Process

CASTING DEFECTS:-

EXTERNAL DEFECTS:-

These defects can be seen on the surface or the edges of the casting. Use a

microscope to see the fine details

TABLE 2.1 EXTERNAL DEFECTS

CATEGORY DEFECT NAME

Gas Related Blisters

Exploded Blisters

Collapsed Blisters

Shrinkage Related Sinks

Filling Related Cold Flow

Short Fill

Laminations

Inclusions Flakes

Die Lube Marks

Surface Deposits

Gate breakout

Thermal- Mechanical Cracks

Hot Tearing

Die Related Soldering

Heat Checking

Die Erosion

Ejection Marks

Page 12: 12BME1107-ABOUT THE COMPANY

12

INTERNAL DEFECTS:-

Table 2.2 Internal Defects

CATEGORY DEFECT NAME

GAS RELATED Gas Porosity

Lubricant Entrapment

Hydrogen Porosity

SHRINKAGE RELATED Shrinkage Porosity

Leakers

Layer Porosity

Filling Related Cold Flow

Laminations

Joints

THERMAL CONTRACTION Cracks

Hot Tearing

EXCESS MATERIAL Flash

OUT OF TOLERANCE War page And Deformation

MACHINING SHOP :

COMPUTER NUMERICAL CONTROL MACHINE ( CNC) :-

There are 15 CNC machines in the machine shop. These machines are used to

perform different machining operations.

The CNC works a/c to the program written by the operator. CNC have two or more

programmable directions of motion called axis. An axis can be linear or rotary.

Common linear axis names are X, Y and Z.

Common rotary axis are A, B & C.

The axis of any CNC machine is required for the purpose of causing the motion

needed for the manufacturing process.

LATHE MACHINE :

There are five lathe machines in the tool room shop.

These all have self-centered chucks.

Operation performed by Lathe Machine are as follows:-

Facing

Boring

Drilling

Threading

Knurling

Parting

Page 13: 12BME1107-ABOUT THE COMPANY

13

Facing: to produce a flat surface at the end of the part and perpendicular to its

axis useful for parts that are assembled with other components. Face grooving

produces grooves for applications such as O-ring seats.

Boring: to enlarge a hole or cylindrical cavity made by a previous process or

to produce circular internal grooves

Drilling: to produce a hole which may be followed by boring to improve its

dimensional accuracy and surface finish.

Parting: also called cutting off, to cut a piece from the end of a part, as is

done in the production of slugs or blanks for additional processing into

discrete products.

Threading: to produce external or internal threads.

Knurling: to produce a regularly shaped roughness on cylindrical surfaces, as

in making knobs and handles

Fig 8 Operation in lathe

MILLING MACHINE:-

Milling includes a number of highly versatile machining operations taking place in a

variety of configurations with the use of a milling cutter-a multi-tooth

tool that produces a number of chips in one revolution.

Milling Machines are of three types :-

Column and Knee type Milling machine:-

Page 14: 12BME1107-ABOUT THE COMPANY

14

Used for general-purpose milling operations, column-and-knee-type machines

are the most common milling machines. The spindle on which the milling

cutter is mounted may be horizontal.

Fig 9 Milling Machine

Fig 10 Milling Machine

Bed-type Milling Machines. In bed-type machines, the worktable is mounted

directly on the Cutters bed, which replaces the knee and can move only

longitudinally

Fig 11 Bed Milling Machine

Page 15: 12BME1107-ABOUT THE COMPANY

15

DRILLING MACHINE:-

Drilling machines are used for drilling holes, tapping, reaming, and small-diameter

boring operations. The most common machine is the drill press, the major

components. The work piece is placed on an adjustable table, either by clamping it

directly into the slots and holes on the table or by using a vise, which in turn is

clamped to the table. The drill is lowered manually by a hand wheel or by power feed

at preset rates. Manual feeding requires some skill in judging the appropriate feed

rate.

Reaming is an operation used to (a) make an existing hole dimensionally more

accurate than can be achieved by drilling alone, and (b) improve its surface finish.

Fig. 11 Drilling Machine

GRINDING MACHINE

Grinding is used to finish work pieces that must show high surface quality (e.g.,

low surface roughness) and high accuracy of shape and dimension.

Fig 12 Grinding Machine

Page 16: 12BME1107-ABOUT THE COMPANY

16

ELECTRO DISCHARGE MACHING :

Electric discharge machining provides an effective manufacturing technique that

enables the production of parts made of special materials with complicated geometry

which is difficult to produce by conventional machining processes. Controlling the

process parameters to achieve the required dimensional accuracy and finish placed this

machining operation in a prominent position. From that reason, electric discharge

machining has found broad applications in industry. The absorbing interest for electric

discharge machines has resulted great improvements in EDM technology. Nowadays,

sophisticated electric discharge machines are available for most of machine shop

applications

Basically Electric Discharge Machining (EDM) is a process for eroding and removing material by

transient action of electric sparks on electrically conductive materials. This process is achieved by

applying consecutive spark discharges between charged work piece and electrode immersed in a

dielectric liquid and separated by a small gap. Usually, localized breakdown of the dielectric liquid

occurs where the local electrical field is highest. Each spark melts and even evaporates a small

amount of material from both electrode and work piece. Part of this material is removed by the

dielectric fluid and the remaining part solidifies rapidly on the surfaces of the electrodes. The net

result is that each discharge leaves a small crater on both work piece and electrode. Application of

consecutive pulses with high frequencies together with the forward movement of the tool electrode

towards the work piece, results with a form of a complementary shape of the electrode on the work

piece...

Page 17: 12BME1107-ABOUT THE COMPANY

17

PAINT SHOP :

The component is passed into degreasing tank. It is addition of pagancleanal-124

(200gm) and water (100 ltr). Temperature of the tank is 55-65 degree Celsius. It removes

oil, dust from the component.

Then it is rinsed in cold water tank to remove oil and dust.

It is then passed into achromatizing tank. Achrom chemical is coated on the component.

Passed into oven at 100-110 degree Celsius.

Second coat of paint is done on paint booth followed by the first.

After that clear coat (leather coat) is done on third paint booth.

Then it is passed into baking room at 140-150 degree Celsius.

Page 18: 12BME1107-ABOUT THE COMPANY

18

WORK DONE AT THE INDUSTRY

DESIGN OF CLUTCH HOUSING

COMPANY:-HERO Moto Corp

Clutch Housings is a mostly used part which holds the clutch disks of the vehicles.

Fig 13 Clutch Housing

DESIGN OF CLUTCH MASTER SPACER

Fig 14 Clutch Master Spacer

Page 19: 12BME1107-ABOUT THE COMPANY

19

Fig. 15 Clutch Pressure Plate

Page 20: 12BME1107-ABOUT THE COMPANY

20

PROJECT

DESIGN OF AUTOMATIC SEALING MACHINE

Fig 16 vertical vacuum sealing machine

About The Machine :-

Vacuum sealing machine at RICO, Dharuhera was manually operated. It was press

operated machine i.e. the engineer/technician have to press the pedal in order to seal the

package. Machine had two coils (heating coils) which melted the package and helped in

packing the machine

Firstly, the package containing the component was placed between the jaws as wells as

the heating coils.

Then the air inside the package was removed using the vacuum pump which removed all

the air present inside the package.

Then the jaws closes making the packaging air tight.

Then through some mechanism the heating coils pressed against each other melting the

packing material.

Heating coils were pressed for 2-3 seconds.

Then the jaws opens and the package was removed.

Page 21: 12BME1107-ABOUT THE COMPANY

21

Aim:-

To design 3D model of vacuum sealing machine considering the problems faced during

packing of the finished products.

To learn Pro E modelling software.

To make the machine automatic (pneumatic controlled).

Design Constraints :-

Dimensions of the machine.

Material used to make different parts.

Problems :-

The sealing machine used at RICO Dharuhera was vertical.

Person who was sealing the finished product have to hold the packet.

This led to errors such as partial vacuum, improper seal, time consumed was high.

Changes In Design:-

Orientation of machine was changed from horizontal to vertical.

Machine was designed horizontally so as to remove the effort required for lifting the

packet for a longer time.

Secondly to remove the effort of holding the package a small slab was incorporated into

the design which would help to support the weight to the package.

Problems such as partial vacuum was also eliminated as the vacuum system could create

vacuum in the package kept stationary on the slab and also there would be less

misalignment during packaging.

Space was provided for pneumatic valves and pipes.

Page 22: 12BME1107-ABOUT THE COMPANY

22

Fabrication of machine:-

The machine was made horizontal keeping the components in position.

Secondly extra sheet metal were added to close off the space so in order to prevent the

dust from entering the package.

Sheet metal were welded to the machine.

Pneumatic system was prepared to fit in the space.

Pedal now acted as a pneumatic actuator when pressed pneumatic pistons were actuated

and the jaws were closed.

Pneumatic solenoids were used to provide the required pressure of air.

Stand was made separately to support the machine alignment.

Then slab was added (made of sheet metal thick sheet) to the base of the machine to

support the package.

Fig 17 Horizontal Automated vacuum sealing machine

Page 23: 12BME1107-ABOUT THE COMPANY

23

CONCLUSION

Summer training undergone at RICO Auto Industries, Dharuhera (H.R) helped me develop new

skills such as learning Pro E software and basics of AutoCAD which is very essential from

industrial point of view. During this internship, I got a golden opportunity to interact with highly

skilled and knowledgeable employees of the company who not only explained me all the

machining process but also provided me with the essential knowledge of how each and every

machine worked and how was one different from the other. This internship not only made me

learn new things but also helped me in framing the clear picture of what we study during the

engineering course such as the entire process from designing to fabrication of the component,

factors that need to be considered to bring even slightest change to component, etc. The

vocational training is helping me throughout my studies as well as my engineering career.

Page 24: 12BME1107-ABOUT THE COMPANY

24

REFERENCES

Manufacturing Engineering and Technology (Fourth Edition) by Serope Kalpakjain and

Steven R.Schmid

Wikipedia (https://en.wikipedia.org)

http://www.themetalcasting.com/

http://www.ehow.com/

http://www.ricoauto.com/

RICO Corporate Presentation(2012)