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 PLACECORE SHOP

FOUNDRY CORE SHOP

SHELL CORE BLOWER MACHINE

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 11.4 DICOR BLOCK WATER JACKET CORE BOX SET 21.4 DICOR BLOCK WATER JACKET CORE BOX SET 32.2 DICOR BLOCK WATER JACKET CORE BOX SET 12.2 DICOR BLOCK WATER JACKET CORE BOX SET 22.2 DICOR BLOCK WATER JACKET CORE BOX SET 32.2 DICOR BLOCK WATER JACKET CORE BOX SET 44 DL BLOCK WATER JACKET CORE BOX SET 34 DL BLOCK WATER JACKET CORE BOX SET 4486 MAGNA BLOCK WATER JACKET CORE BOXEXISTING EJECTION SYSTEM

All core boxes are having inbuilt ram ejection system.

4 nos. pneumatic cylinders are mounted on core box.EXISTING EJECTION SYSTEMCORE BOX

Cylinder operation is pneumatic & cylinder seal kit is made up of asbestos rope.EXISTING EJECTION SYSTEMCYLINDER PISTONASBESTOS SEAL

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.PROBLEMS WITH EXISTING SYSTEM

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.

CORE STUCK TO RAM SIDEMACHINEMANMATERIALMETHOD Process parameterChange of parameter Regular operatorLack of knowledgeChange of sealingChange of resin Spring ejection Pneumatic ejection CAUSE & EFFECT DIAGRAM :

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

ROOT CAUSE

HYARAULIC EJECTION SYSTEM Space limitation for mounting of hydraulic cylinderRAM OR FRAME

HYARAULIC EJECTION SYSTEMCYLINDER TAKEN FOR TRIAL AVALIABLE SPACE FOR CYLINDER IN RAM BORE( OD=65mm,Stroke=25mm,ID=40mm) (ID=90mm & Length=100mm)

HYARAULIC EJECTION SYSTEMCYLINDER MOUNTING PLATE CYLINDER MOUNTED WITH PLATE ON RAM

HYARAULIC EJECTION SYSTEM NEW DESIGNED CYLINDER ACCORDING TO AVAILABLE SPACE

HYARAULIC EJECTION SYSTEMGUIDE ROD & BUSH MOUNTING PLATE WELDED TO THE RAM. Spacer (OD=50mm & L=100MM

HYARAULIC EJECTION SYSTEMEJECTION PINS GUIDED FROM HEATER PLATE DRILLED HOLEEJECTION PINS PUSHING POINTS

ADJUSTABLE SPACER GUIDE ROD & BUSHEJECTION PLATECORE BOX WITH HEATER PLATEASSEMBLY OF HYARAULIC EJECTION SYSTEM

PERFORMANCE OF HYDRAULIC EJECTION SYSTEM

COMPARISION OF CORE REJECTION TRENDApprox. 3 nos. cores/shift & 8 nos. cores/dayApprox. 1 nos. core/shift & 2 nos. cores/dayPRODUCTION TARGET: 90 CORES/SHIFT & 250 CORES/DAY

Chart1

10MONMON

9TUETUE

8WEDWED

9THUTHU

10FRIFRI

8SATSAT

Rejection

Column1

Column2

Rejection trend of existing Ejection system

Sheet1

RejectionColumn1Column2

MON10

TUE9

WED8

THU9

FRI10

SAT8

To resize chart data range, drag lower right corner of range.

Chart1

1

2

1

1

2

1

Rejection

Rejection trend of hydraulic ejection system

Sheet1

Rejection

MON1

TUE2

WED1

THU1

FRI2

SAT1

To resize chart data range, drag lower right corner of range.

FEATURES OF HYDRAULIC EJECTION SYSTEM 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 ?

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