Process re validation
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Transcript of Process re validation
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MAHAVIR CASTERS PLANT -3
IMPROVEMENT PROJECT
MAHAVIR DIE CASTERS PLANT - III
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MAHAVIR CASTERS PLANT -3
PROJECT THEME
Process Revalidation For Grip Casting By
Bharat [email protected]
MAHAVIR DIE CASTERS PLANT - III
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MAHAVIR CASTERS PLANT -3
• Process should be as per aesthetic part.• Help to reduce soldering.• Increase plunger life.• Increase die life.• Increase machine life.• Reduce flow porosity.
MAHAVIR DIE CASTERS PLANT - III
Why we need to revalidate?
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MAHAVIR DIE CASTERS PLANT -III
How?
• As we know aesthetic casting doesn't need casting pressure up to 800 kg/cm^2 .• Casting appearance should be good with respect to non filling, crack, & flow porosity.• As per pq^2 diagram
P=Ct*Vg^2
Here,P= pressure on the plunger face:,Ct= composite discharge coefficient,Vg= velocity of the liquid metal at the Cavity gate.
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MAHAVIR DIE CASTERS PLANT -III
From above equation, we can say that,If reduce gate velocity then pressure on plunger face will reduce with same ratio.
Let’s take an example: Machine: 400TPart: Grip KTRPlunger dia: 70mmInjection piston head dia: 101mmStatus: AestheticN2 charging pressure in Intensification accumulator: 90kg/cm2(It should be 7 kg/cm2 less than minimum Required intensification charging pressure.)Pressure build up time:200msNow from above data,We have to set casting pressure according to aesthetic part Cp= Ip*(d/D)^2Cp=Casting pressureIp= Intensification pressured= Plunger diaD=Injection piston head dia
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MAHAVIR DIE CASTERS PLANT -III
So from above eq’n
Cp=Cp*(d/D)^2
For same machine and die “d” & “D” constant Now eq’n become
Cp ὰ Ip (Casting pressure directly prepositional to intensification)Means as I increase Ip, Cp will directly increase with same ratioAndIp increase when intensification charging pressure will increase
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MAHAVIR DIE CASTERS PLANT -III
So now I conclude as we have to minimize intensification charging pressure as decrease to intensification pressure as decrease casting pressure which isnot required as much as technical parts.
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MAHAVIR DIE CASTERS PLANT -III
Let’s talk about pressure build up time:Pressure build up time is a time taken to achieve max intensification from intensification charging pressure.
Pressure build up time
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MAHAVIR DIE CASTERS PLANT -III
• To understand how its work lets take example:pressure build up time control by a valve as shown in image on which no’s of turn Available.N=No’s of turnV=volume of oilv= velocity of oilA=area through which oil has to passt= time taken by volume of oil to flow.Q=discharge
As we know, Q=V/t…………(1)Q=Av………………………………(2)From 1 & 2V/t=Av
(t= V/Av)Now from above eq’nPressure build up time will increase asVolume of oil increase .This volume will increase by opening this valve.
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MAHAVIR DIE CASTERS PLANT -III
• So we can reduce plunger velocity. • Reduce intensification charging pressure.• Increase intensification valve turn.• And to avoid shrinkage we can increase intensification phase speed & reduce Intensification charging pressure as shown in screen shot image.
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MAHAVIR DIE CASTERS PLANT -III
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Pressure build up time
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Benefit to organization:
• Increase plunger life.• Increase machine capability. • Minimize injection unit leakage.• Increase machine clamping capability.• Increase die life.
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MAHAVIR DIE CASTERS PLANT -III
MAY JUNE JULY0
10
20
30
40
50
60
Monthly Plunger Consumption
70mm 80mm
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MAHAVIR CASTERS PLANT -3
THANKS
MAHAVIR DIE CASTERS PLANT - III