12BME1107-ABOUT THE COMPANY

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Transcript of 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. RICOs 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

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    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

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    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.

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    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

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    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 1000C.

    Raw Aluminum is brought to the furnace on conveyor belts.

    When the Aluminum enters the red hot furnace maintained at 1000C 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

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    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

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    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.

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    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.

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    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.

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    FACT :-

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

    DYCOTE is significantly re