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Transcript of PROJECT QA 2015 Prakash
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To enhance the knowledge management of QA casting
and forging store by making check sheets for critical
dimensions and pictorial inspection procedure
for different families of
castings, forgings and machined components
Vocational Training Project
By
Prakash Bharati
Dept. of Mechanical Engineering
JADAVPUR UNIVERSITY, KOLKATA
Under the Guidance of
Mr. Manpreet Singh Marwah Senior Manager
Materials Engineering Group Quality Assurance
THCM, Jamshedpur
May 25th, 2015 to June 25th, 2015
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Certificate
This is to certify that project report entitled “To make
check sheets for critical dimensions and pictorial
inspection procedure for different families of castings,
forgings and machined components” submitted by
“Prakash Bharati” is a bonafide project work carried
out by him under my guidance. In my opinion the work
fulfills the requirement for which it is being submitted.
Place: THCM, JSR Project Guide Date: 25/06/2015 Mr. Manpreet Singh Marwah
Senior Manager Materials Engineering Group
Quality Assurance THCM, Jamshedpur
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ACKNOWLEDGEMENT
I would like to thank the Management of TATA HITACHI CONSTRUCTION
MACHINERY CO. PVT. LTD. (JAMSHEDPUR) for giving me this wonderful
opportunity to work with highly knowledgeable people on a project of
great importance.
I sincerely acknowledge the help and guidance received from Mr.
Manpreet Singh Marwah (Senior Manager) without whom it would have
been difficult to complete this project work. His constant encouragement
and words of motivation have been a source of inspiration for me. His
guidance from the very first day helped me develop an understanding of
the project.
I owe my deepest gratitude to Mr. Himanshu Pratap Singh (Asst.
Manager) for the valuable inputs provided by him at each and every step
of the project and this project would have been incomplete without his
help.
I acknowledge the help provided by Mr. A.N. Mohanta (Asst. Engineer).His
vast experience in this field helped me to get a better understanding of
this project and his constant help during this period helped me to
complete the project.
I also want to thank Mr. Monikut Sharma (Divisional Manager) &
Mr. Kumar Jagat (Asst. Divisional Manager) for providing us an
opportunity to present this work.
I convey my deep appreciation to all the technical and administrative
staffs at LMS STORE.
PRAKASH BHARATI
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CONTENTS
SL NO. TITLE PAGE NO.
ACKNOWLEDGEMENT 3
CONTENTS 4-6
1 ABOUT TATA HITACHI 7
1.1 INTRODUCTION 7-8
1.2 ENVIRONMENT 9-15
1.3 VISION AND MISSION 16
1.4 CORPORATE SOCIAL RESPONSIBILITY 17-19
1.5 INDUSTRY SOLUTIONS 20-21
2 QUALITY ASSURANCE 22
2.1 INTRODUCTION 23
2.2 FUNCTION 23
2.3 TESTING METHODS 24-28
3 PART-1 : FORMATION OF FAMILIES 29
3.1 INTRODUCTON 30
3.2 PROCEDURE 30
3.3 CONTENTS OF THE TABLE 31 - 33
3.3.1 COMMON TYPES OF PARTS FROM SEVEN MAJOR VENDORS 31
3.4 LIST OF IMPORTANT FAMILIES 34-35
3.4.1 GEAR PLANETARY 34
3.4.2 CARRIER 34
3.4.3 PIN 34
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3.4.4 TOOTH ADAPTER 35
3.4.5 BOSS 35
3.4.6 BUSH 35
3.4.7 SPROCKET 35
4 PART-2 PICTORIAL INSPECTION OF CRITICAL DIMENSIONS 36
4.1 INTRODUCTION 37
4.2 INSPECTION PROCEDURE 37
4.3 PICTORIAL INSPECTION FLOW CHARTS 38-72
4.3.1 BOOM CENTRE BOSS 38-39
4.3.2 ARM BOSS 40-41
4.3.3 BOOM FOOT BOSS 42-44
4.3.4 BUSH 45-47
4.3.5 CARRIER 48-53
4.3.6 CENTRE JOINT BODY 54-56
4.3.7 GEAR PLANETARY 57-58
4.3.8 PIN 59-60
4.3.9 SPROCKET 61-63
4.3.10 TOOTH ADAPTER 64-68
4.3.11 TOOTH POINT 69-72
5 PART-3 CHECKSHEETS FOR CRITICAL DIMENSIONS 73
5.1 INTRODUCTION 74
5.2 CHECK SHEETS 75-95
5.2.1 BOSS 74
5.2.2 BUSH 75
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5.2.3 CARRIER 76
5.2.4 CENTRE JOINT BODY 77
5.2.5 GEAR PLANETARY 78
5.2.6 PIN 79
5.2.7 SPROCKET 80
5.2.8 TOOTH ADAPTER 81
5.2.9 TOOTH POINT 82
5.2.10 BEARING 83
5.2.11 COVER 84
5.2.12 DRUM 85
5.2.13 GEAR SUN 86
5.2.14 IDLER 87
5.2.15 NUT 88
5.2.16 SHAFT 89
5.2.17 SHROUD 90
5.2.18 SLEEVE 91
5.2.19 SPINDLE 92-93
5.2.20 YOKE 94
6 SUMMARY 96
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ABOUT TATA HITACHI
1.1) INTRODUCTION Tata Hitachi Construction Machinery Co. Pvt. Ltd, the Leader in Construction Equipment in India, enhances the operational performance of its customers, leading to improving their profitability and competitiveness by offering constructive solutions. Tata Hitachi is a subsidiary company of Hitachi Construction Machinery Co. Ltd., which holds 60% share, and Tata Motors Ltd holding the balance 40%. The company commenced manufacturing of construction equipment in 1961, as a division of TELCO. In 1984, it entered into a technical collaboration with HCM, Japan for manufacturing state of the art hydraulic excavators. Tata Hitachi is focused on capitalizing the opportunity in the domestic arena for which the key market segments are Excavators, Wheeled Products, Cranes and Others. Tata Hitachi's consistent growth and success have been built on the foundation of our ability to understand customers' needs and provide Equipment and Support solutions that increase profitability and competitiveness for them. What we call Reliable Solutions. Our capabilities to deliver Reliable Solutions starts with our comprehensive range of Equipment that ensures that the customer has exactly the right kind of equipment for all Mining, Infrastructure, Construction and Agricultural needs. The construction industry involves heavy use of excavators, wheel loaders, and backhoe loaders. Tata Hitachi's range of excavators starting at 2 tonnes with a maximum size of 120 tonnes is made in the country. But sizes even bigger than this including the giant 250 tonne excavator have been brought in from Tata Hitachi's Principals, Hitachi Construction Machinery Limited, Japan. Tata Hitachi is one of the largest manufacturers of construction equipment in the country and has three manufacturing plants - at Jamshedpur in Jharkhand, at Dharwad in Karnataka and at Kharagpur in West Bengal. It also has a full – fledged Design and Development set-up for developing indigenous and collaborated equipment’s . Hitachi is actively participating in creating the new R&D facilities at Kharagpur with the aim to make the new centre a global R&D hub. Our endeavour to provide Reliable solutions is enabled by our widespread network, which ensures that wherever they are, our customers are never too far away from us. Tata Hitachi Dealers provide support to the customers through parts and expert service. Tata Hitachi takes pride in its marketing and
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service network of 230+ touch points that enables it to have one of the largest distribution networks in the country. Our focus is also on Value added Service offerings such as Full Maintenance Contracts, which complete our package to our customers and enable him free up precious resources for his core activities. Specialized reconditioning and refurbishing services are offered to ensure that the utility of the equipment is extended and life cycle costs brought down.
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1.2) ENVIRONMENT THCM is in the business of designing, manufacturing, marketing, selling
and servicing a wide range of construction equipment as shown in table below
Hydraulic Excavators
Mini Excavators
Backhoe
Model Engine Power Operating Weight Bucket Capacity
TMX 20-2 28 HP 2,200 kg 0.04 - 0.12 m3
ZAXIS 50 36 PS 4,810 kg 0.16 - 0.18 m3
EX 70 55 PS 7,000 kg 0.10 - 0.30 m3
ZAXIS 75 55 PS 7,400 kg 0.30 m3
EX 110 76 PS 11,000 kg 0.25 - 0.65 m3
ZAXIS 120H 90 PS 12,800 kg 0.19 - 0.70 m3
Shovel
EX 110 76 PS 11,600 kg 0.6 m3
Midi Excavators
Backhoe
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Model Engine Power Operating Weight Bucket Capacity
EX 200 LCi 125 PS 20,000 kg 0.8 - 0.91 m3
ZAXIS 210 LCH 150 PS 21,000 kg 0.9 - 1.1 m3
ZAXIS 220 LC 170 PS 21,700 kg 0.45 - 1.0 m3
EX 350 LCH-V 230 PS 34,000 kg 1.3 - 1.90 m3
ZAXIS 370 LCH 250 PS 35,400 kg 1.3 - 2.1 m3
Shovel
EX 200 LCi 125 PS 20,150 kg 1.32 m3
Large Excavators
Backhoe
Model Engine Power Operating Weight Bucket Capacity
ZAXIS 450 H 320 PS 45,100 kg 1.9 - 3.0m3
ZAXIS 650 H 400 PS 57,600 kg 3.3 - 3.8 m3
EX 1200 V 760 HP 1,11,000 kg 5.0 - 6.5 m3
EX 1900-6 1086 HP 1,91,000 kg 4.4 - 12.0 m3
EX 2600-6 1500 HP 2,54,000 kg 17.0 m3
EX 3600-6 1900 PS 3,59,000 kg 22 m3
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EX 5600-6 2 x 1500 HP 5,37,000 kg 34 m3
Shovel
ZAXIS 450 H 320 PS 46,100 kg 2.6 m3
ZAXIS 650 H 400 PS 60,500 kg 3.0 - 4.0 m3
EX 1200 V 760 HP 1,11,000 kg 5.9 - 6.5 m3
EX 1900-6 1086 HP 1,92,000 kg 11 m3
EX 2600-6 1500 HP 2,52,000 kg 15 m3
EX 3600-6 1900 PS 3,62,000 kg 21 m3
EX 5600-6 2 x 1500 HP 5,33,000 kg 29 m3
EX 8000-6 2 x 1940 HP 8,11,000 kg 40 m3
Excavator Loaders
Model Engine Power Operating Weight Bucket Capacity
TH 76 76 PS 7,200 kg 0.09 - 0.25 m
3 (B/H)
1 m3 (Loader)
TH 86 86 PS 7,500 kg 0.09 m
3 - 0.30 m
3 (B/H)
1 m3 (Loader)
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Wheel Loaders
Model Engine Power Operating Weight Bucket Capacity
TWL 3034 101.5 PS 10,470-10,600 kg 1.5 - 2.5 m3
TL 360 Z 130 PS 12,185 kg 1.5 - 3.0 m3
ZW 220 223 PS 17,800 kg 2.7 - 4.5 m3
ZW 310 299 PS 22,400 kg 3.4 - 4.2 m3
Transit Mixers
Model Engine Power Max Drum
Speed
Nominal
Capacity
TM 06
Super 51.4 Kw/70 HP 14 rpm 6 m
3
TM 08 75.7 Kw/101.5
HP 14 rpm 8 m
3
Dump Truck
Model Engine Power Max GMW Max Payload
EH 600 400 HP 58,490 kg 35.3 Ton
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Compactors
Name Model Engine Power Operating Weight
Soil Compactor VM3 102 HP @ 2300rpm 11,010 kg
Tandem Roller VTA 90 102 HP @ 2300rpm 9,500 kg
Motor Graders
Model Engine Power Operating Weight
TG 14 140 HP 14,040 kg
Cranes
Crawler Cranes
Model Engine Power Max Lifting Capacity
TFC 75 120 PS 25,000 kg
TFC 280 210 HP 75,000 kg
KH 500 250 PS 1,00,000 kg
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Hydraulic Cranes - Hitachi Sumitomo
Model
Max.
Lifting
Capacity
Load
Radius
( Mtrs)
Max Boom Length
(Mtrs)
Fly Jib
Length
(Mtrs)
SCX 400 40 T 3.7 46 15
SCX 550 55 T 3.7 42 15
SCX 700 70 T 3.5 54 18
SCX 800-
2 80 T 3.3 54.5 18
SCX 900-
2 90 T 4.0 6 28
SCX
1200-2 120 T 4.5 72 28
SCX
1500-2 150 T 4.1 75 28
SCX
2800-2 (N) 275 T 4.3 91.45 36.6
SCX
2800-2 (L) 80 T 9.4 61 61
6000 SLX-
N 500 T 6.0 96(H)/108(L)/72(Luff) 72(Luff)
6000 SLX-
T 500 T 7.3 96(H)/120(L)/84(Luff) 84(Luff)
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Tunnel Boring Machine - Hitachi Zosen
Type Diameter
Slurry Ø 2.53 to Ø 14.14 Mtrs
Earth Pressure Balanced Ø 2.336 to Ø 17.5 Mtrs
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1.3) Vision and Mission
VISION
Reliable Solutions
for Building a Greater
Tomorrow
MISSION
Be the preferred partner for providing reliable
solutions for mining and infrastructure sectors.
While dominating the domestic market, we will
become a global manufacturing and development
hub. Our hall mark shall be at our motivated people
customer-centric culture, superior technologies
and strong partnerships,all working safety in
unison with environment and safety.
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1.4) CORPORATE SOCIAL RESPONSIBILITY:
Tata Hitachi (THCM) has identified Corporate Social Responsibility (CSR) as on one of the Key Business Process. Tata Hitachi is committed to improving the quality of life of its identified communities located in and around the units of its operations. It shall strive to achieve this through periodical assessment of the needs of its communities and the continuous enrichment of the initiatives, designed to facilitate a process through which Tata Hitachi and its communities shall work as equal partners of social development. TATAHITACHI shall also strive to provide opportunity to its employees to volunteer their managerial, technical and specialized skills and services in order to enrich their lives, as well as to enable the company achieve its stated social responsibility of building strong communities, in creating a sustainable environment in and around its facilities. THCM CSR initiatives at Jamshedpur, Dharwad and Kharagpur is broadly
divided into:
Literacy Initiative:
THCM in its operational areas around its Plants at all locations has identified
schools which are catering mainly to underprivileged section of society.
Children from these schools are selected on merit cum need basis for providing
scholarships (50% of school fees), Books and uniforms.
THCM also provides infrastructure support to these schools to enhance the
quality of education to the children. THCM has helped these schools by building
a library, computer laboratory, boundary wall, vocational training workshop,
drinking water facilities for these schools.
THCM Graduate Engineer Trainees (GET’s) conduct an annual inter school
competition called JAGRITI for students of these schools for wherein there are
events like debate, quiz, extempore speech, singing, creative design, dancing
and drawing. This event provides a platform for these children to unleash their
talent, which helps them in developing their leadership quality, self confidence
and personality.
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Health Care Initiative:
THCM conducts Medical Check- up programmes in sponsored villages and
schools and provides treatment for various ailments. THCM also undertakes
repairing of tube wells and open wells for safe drinking water in sponsored
villages.
Rural Development Initiative:
THCM conducts various training programmes in the villages to enhance their
agricultural income through modern techniques. THCM assists the villagers in
reclamation of their barren land to bring it under cultivation. The Company also
helps the villagers in creating water harvesting structures to store rain water
for their use in house hold activities and other activities like pisciculture , duck
farming, vegetable farming etc. THCM has provided pipes and cable connection
for lift irrigation project in the Hurlung village, which has enabled the villagers
to bring 30 acres of land under multiple cropping. Good varieties of high yield
hybrid seeds were also given to farmers for vegetable cultivation.
Skill Development Initiative:
The Company has set up an Operator Training School at Kharagpur. It rests on
multiple pillars of skill building, social entrepreneurship and training. The
school imparts driving and servicing skills for excavators and backhoe loaders to
the unemployed youth to enhance their employability as operators for
construction equipment both in India and abroad. And as a policy 50 per cent
of the seats have been kept reserved for SC and ST candidates. The school has a
modern hostel, multiple class rooms supported by electronic visual aids and to
add to this the Company has put in place its state-of-the art machines amongst
others for practical sessions and for imparting world class training. The
program includes theory on equipment, practical and hands on training for
aggregates. A team of well trained and experienced personnel in the field of
training from the Company is leading the initiative.
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Operator cum mechanic training at Operator Training Centre
The initiative does not end here. The Company has taken it even further
wherein it maintains a data of trained personnel and shares information on its
trained operators to its dealers at all levels and new customers entering the
business for employment. It will ultimately usher in a supply chain
management system connecting supply of trained resource to its demand. This
will be noteworthy and is sure to make a sustainable contribution to the hugely
growing infrastructure sector in the country. Our engagement process at the
training centre goes a little beyond training. It aims at creating a corporate
sustainability programme, creation of human capital, leadership, and skill
building. Ultimately the emerging 3D vision out of this will focus on positive
economic value addition , social entrepreneurship, flanked by the twin pillars of
growth and sustainability. To further enhance the employability arena, the
Company provides four wheel driver training to village youths and tailoring to
ladies groups in the villages.
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1.5) INDUSTRY SOLUTIONS:
Mining
Tata Hitachi Construction Machinery (THCM) has been in the frontline in
providing complete solutions to the Mining Industry from the early beginnings
in cable shovels and Backhoes in the 60’s. With the advent of the Hydraulic
Excavators era, the Company introduced first the UH series and then the EX
series in India giving a new dimension to the Indian mining industry in
productivity and maintenance costs. The EX1200, a 100T class of excavator with
6.5 cum bucket has been a significant player in the Mining segment cutting
across various applications such as Coal, Iron ore and Limestone excavation.
The focus has been the profitability of customers through high fuel efficiency
and low operating costs . The Company also introduced the concept of the Full
Maintenance Contract which ensured the availability of equipments to the
customers and ensured better life and higher utilization levels of the
Equipment. The product mix in the Mining sector includes a range of
Excavators made in India complemented by Hitachi Construction Machinery’s
wide range going up to 800 T operating weight. These are matched with a
range of Dump Trucks.
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Infrastructure
Tata Hitachi Construction Machinery (THCM) offers a variety of solutions for
the infrastructure space. We straddle the entire range of equipment class by
tonnage; starting from the Mini Class of machines in the 2-7 T range, which
includes tracked excavators and wheeled equipment like the Excavator loaders.
These little masters go about doing their jobs deftly across applications while
remaining with in strict conforms of owning and operating costs.
The 10 - 20T class of tracked excavators, compactors and motor graders are the
“builders” that have literally built all key infrastructure in the last 20 years, then
be it India’s first Express highway between Mumbai & Pune in Roads, The iconic
Konkan Railway in Rail construction, The Tehri dam in Hydro power & Irrigation
and countless Commercial and Industrial Real estate development projects
across the country. It is hard being at a construction site without spotting one
these orange workhorses around you.
The 35T and above, class of equipment are called for when special applications
is the need of the hour, whether it is dredging of waterways, quarrying to
produce the Granite we all admire in our homes, offices and commercial spaces
or Material handling at Coal pit heads and ports, a THCM “hand” would always
be at hand and will prove to be more than handy.
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QUALITY
ASSURANCE
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2.1) INTRODUCTION Quality Assurance is a complete system to assure the quality of products or services. It is not only a process, but a complete system including also control. It is a way of management. Quality Assurance is a system for evaluating performance, service, of the quality of a product against a system, standard or specified requirement for customers. Quality Assurance is fundamentally focused on planning and documenting those processes to assure quality including things such as quality plans and inspection and test plans. QA is a part of quality management focused on providing confidence that quality requirements will be fulfilled. Quality assurance deals with the prevention of problems. Quality Assurance department deals with checking of the quality at every step so as to guarantee the production of a quality product. The major work of the quality department is to check for reports for any failure and find the causes of failure. The quality assurance has to check the quality of the incoming materials like the castings which come in from the vendors to check if they contain any defects like blowholes, shrinkage etc. It also has the responsibility of checking of the various sub parts in the intermediate stages such as after heat treatment, after machining, after or during fabrication in case any problem arises. It deals with prevention of quality problems through planned and systematic activities including documentation. It also deals with how to establish a good quality management system and the assessment of its adequacy& conformance audit of the operation system & the review of the system itself. QA is applied to physical products in pre-production to verify what will be made meets specifications and requirements, and during manufacturing production runs by validating lot samples meet specified quality controls. Two principles included in Quality Assurance are: "Fit for purpose", the product should be suitable for the intended purpose; and "Right first time", mistakes should be eliminated. QA includes management of the quality of raw materials, assemblies, products and components, services related to production, and management, production and inspection processes.
2.2) FUNCTION
The incoming materials are a majority of casting subparts coming from different vendors. Hence the main aim of the QA is to check whether the casting is made by the vendor is of the required quality or not and also whether they are made using the process specified by them in the contract. The function of the QA is also to check the cause of failure in case any failure is
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reported by the customer and check whether it is due to the casting or due to the wrong usage by the customer or any other reason for the matter
2.3) TESTING METHODS
. The major methods used by the QA department are-
Ultrasonic testing
Magnetic particle test
Dye penetration test
Radiographic test
Dimensional testing
ULTRASONIC TESTING
In ultrasonic testing (UT), very short ultrasonic pulse-waves with center frequencies ranging from 1-10 Hz are transmitted into materials to detect internal flaws or to characterize materials. Ultrasonic testing is often performed on steel. It is a form of non-destructive testing used in many industries including aerospace, automotive and other transportation sectors. In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed over the object being inspected. The transducer is typically separated from the test object by a couplant (such as oil) or by water, as in immersion testing. However, when ultrasonic testing is conducted with an Electromagnetic Acoustic Transducer (EMAT) the use of couplant is not required.
There are two methods of receiving the ultrasound waveform: reflection and attenuation. In reflection (or pulse-echo) mode, the transducer performs both the sending and the receiving of the pulsed waves as the "sound" is reflected back to the device. Reflected ultrasound comes from an interface, such as the back wall of the object or from an imperfection within the object. The
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diagnostic machine displays these results in the form of a signal with an amplitude representing the intensity of the reflection and the distance, representing the arrival time of the reflection. In attenuation (or through-transmission) mode, a transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Imperfections or other conditions in the space between the transmitter and receiver reduce the amount of sound transmitted, thus revealing their presence. Using the couplant increases the efficiency of the process by reducing the losses in the ultrasonic wave energy due to separation between the surfaces.
MAGNETIC PARTICLE TEST
Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and slightly subsurface discontinuities in the various parts being made here. The process puts a magnetic field into the part. The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs when the electric current is passed through the test object and a magnetic field is formed in the material. Indirect magnetization occurs when no electric current is passed through the test object, but a magnetic field is applied from an outside source. The magnetic lines of force are perpendicular to the direction of the electric current which may be either alternating current (AC) or some form of direct current (DC) (rectified AC). The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to leak, since air cannot support as much magnetic field per unit volume as metals. Ferrous iron particles are then applied to the part. The particles are in a wet suspension. If an area of flux leakage is present, the particles will be attracted to this area. The particles will build up at the area of leakage and form what is known as an indication. The indication can then be evaluated to determine what it is, what may have caused it, and what action should be taken, if any. The magnaflux machine is used here for the magnetic particle inspection.
DYE PENETRATION TEST
Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or penetrant testing (PT), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-ferrous materials and ferrous materials; although for ferrous components magnetic-particle
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inspection is often used instead for its subsurface detection capability. LPI is used to detect casting, forging and welding surface defects such as hairline cracks, surface porosity, leaks in new products, and fatigue cracks on in-service components. DPI is based upon capillary action, where surface tension fluid low penetrates into clean and dry surface-breaking discontinuities. Penetrant may be applied to the test component by dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess penetrant is removed and a developer is applied. The developer helps to draw penetrant out of the flaw so that an invisible indication becomes visible to the inspector. Inspection is performed under ultraviolet or white light, depending on the type of dye used - fluorescent or non-fluorescent (visible).
RADIOGRAPHIC TEST
Radiographic Testing (RT), or industrial radiography, is a nondestructive testing (NDT) method of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic radiation (high energy photons) to penetrate various materials.
Either an X-ray machine or a radioactive source, like Ir-192, Co-60, or in rarer cases Cs-137 are used in a X-ray computed tomography machine as a source of photons. Neutron radiographic testing (NR) is a variant of radiographic testing which uses neutrons instead of photons to penetrate materials. This can see very different things from X-rays, because neutrons can pass with ease through lead and steel but are stopped by plastics, water and oils.
Since the amount of radiation emerging from the opposite side of the material can be detected and measured, variations in this amount (or intensity) of radiation are used to determine thickness or composition of material. Penetrating radiations are those restricted to that part of the electromagnetic spectrum of wavelength less than about 10 nanometers . Defects such as delamination’s and planar cracks are difficult to detect using radiography, which is why ultrasonic is the preferred method for detecting this type of discontinuity.
DIMENSIONAL TESTING
Various measuring instruments are used in order to check and determine the dimensions of the various parts. A few of them are-
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a) HEIGHT GAUGE-
A height gauge is a measuring device used either for determining the height of the parts. Mitutoyo digital height gauge is used here. It can measure maximum up to height of 600mm. it has an automatic zero setter for taking our own reference origin or zero line.
b) MICROMETER
A micrometer sometimes known as a micrometer screw gauge, is a device incorporating a calibrated screw widely used for precise measurement of components. Here two types of micrometres are used digital micrometre and a general micrometre. They have their own respective calibrating sticks for calibration. They measure a maximum of 300mm. In case of any zero error the digital micrometre can be set to zero in that case. But in the case of the other micrometre it is necessary to take into consideration the zero error.
c) VERNIER CALIPER
A vernier scale is a device that lets the user measure more precisely than could be done by reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the measurement lies in between two of the marks on the main scale. Two types of vernier calipers are used here- digital vernier caliper with a zero error adjuster and a dial indicating vernier caliper whose zero error has to be checked and taken into consideration.
d) BORE GAUGE
A bore gauge is tool used for checking the dimension of a part. It is not used for the measurement of the inner diameter of the various parts. Bore gauge is calibrated using a micrometer. The deviation or zero error is calculated by checking the deflection in the dial of the bore gauge. Bore gauge tells us by how much a certain dimension varies from a certain given dimension but it does not help us in measurement of the dimension of the part.
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e) BEVEL PROTRACTOR
A bevel protractor is a graduated circular protractor with one pivoted arm; used for measuring or marking off angles. Sometimes Vernier scales are attached to give more precise readings. It has wide application in architectural and mechanical drawing, although its use is decreasing with the availability of modern drawing software or CAD. Universal bevel protractors are also used by toolmakers; as they measure angles by mechanical contact they are classed as mechanical protractors. The bevel protractor is used to establish and test angles to very close tolerances. It reads to 5 minutes or 1/12°] and can measure any angle from 0° to 360°. To measure an angle between the beam and the blade of 90° or less, the reading may be obtained direct from the graduation number on the dial indicated by the mark on the swivel plate. To measure an angle of over 90°, subtract the number of degrees as indicated on the dial from 180°, as the dial is graduated from opposite zero marks to 90° each way. Since the spaces, both on the main scale and the Vernier scale, are numbered both to the right and to the left from zero, any angle can be measured. The readings can be taken either to the right or to the left, according to the direction in which the zero on the main scale is moved.
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PART - 1 TO FORM FAMILIES OF
DIFFERENT PARTS BY
CONSOLIDATING A LIST
FOR ALL THE INCOMING
PARTS TO THE
CASTING/FORGING STORES
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3.1) INTRODUCTION
The THCM plant in Jamshedpur does not have its own foundry, hence the various parts products manufactured by the company are given out to contractors or vendors for being made through casting. Currently there are 39 vendors for casting and Machining parts. The main aim of the project is to form a family of similar products by consolidating various products being made by the vendors into a separate list containing all the basic details of the part. The list contains details of the casting and machining part such as the part number, the description of the part, the vendor code and the quantity of incoming parts to the casting and forging stores.
3.2) PROCEDURE
1) The list of incoming parts was downloaded from SAP for the period 01/04/2014 to 31/03/2015.
2) Total incoming part for 1 year = 1,46,976 units
3) Total incoming parts was filtered and sorted for 7 major vendors since contribution from these vendors are 1,22,909 units which is 83.62% of total incoming components. The seven vendors are listed below:
1) JMT Auto Ltd.
2) Mayura Steels Pvt. Ltd.
3) Ramakrishna Forging Pvt. Ltd.
4) India Forging and Stamping (IFS)
5) India Forging and Engineering (IFE)
6) Multitech Component Pvt. Ltd.
7) Newco Auto
4) Different families were formed based on the similar category of components from the total incoming parts of one year. The different families formed are Gear Planetary, Carrier, Pin, Tooth adapter, Tooth Point, Boss, Bush, Housing, Yoke, Sprocket, Nut, Gear, Shaft, and Sleeve etc.
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3.3) CONTENTS OF THE TABLE
The table contains the details of the parts such as the part number, its name, the vendor code and the incoming quantity annually.
The contents help give an overlook on the part and help in easy identification and help in tracking of the cast parts. The contents can be further explained as follows:
EXCERPT OF THE TABLE
TABLE 3.3.1: COMMON TYPES OF PARTS FROM SEVEN MAJOR VENDORS:
Part Number Part Name Qty Vendor
TB01034 ADJUSTER ASSY WITHOUT SPRING. 848 S5021M
TB00340 TR.ADJ(W/O SPR) 720 S5021M
TE04688@50 BUSHING(FIN.TURNED) 444 S5021M
3044121 PIN 10 S5021M
3084353 GEAR PLANETARY 2675 R24820
3037936 BOSS 1552 R24820
3082517@80 GEAR;PLANETARY (HOBBING DONE) 1170 R24820
2049585@50 SHAFT;PROP(FINISH TURN) 1126 R24820
1010204@45 SPROCKET 1069 M63200
TB01401 TOOTH ADAPTER 960 M63200
TE06513 TOOTH POINT 960 M63200
TB00204@55 IDLER (WITHOUT F/ HRD)) 804 M63200
SE00729/SF BUSH 2286 M04890
4126209 PIN 18.0X10M.0 1330 M04890
TD08458@50 FLANGE ( W/O BROACH ) 230 M04890
TC02154@60 SHAFT ( WITHOUT SPLINES ) 108 M04890
TE03584 WASHER 2495 J04610
3070162 AXLE 693 J04610
TB00841 BODY 645 J04610
TB00840 SPINDL 631 J04610
084085201@40 PLATE 15 I24820
1025957@40 GEAR;RING(ROUGH TURN) 117 I24820
2033231@20 RIM; SF 26 I24820
2044936@30 SHAFT;PROP(ROUGH TURN) 70 I24820
1022195/SF GEAR;RING (FORGING ) 447 I20780
2033066 BOSS 41 I20780
2040439@20 TRACK ADJUSTER CYL ROUGH MACHINED 10 I20780
3201N21@30 INTER HOIST SHAFT ( ROUGH TURN ) 4 I20780
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1) PART NUMBER
All the different parts of a machine have their own specific number. They vary according to the part and according to the project as well. The casting parts have a “/C” in the end after the numerical number. For example-MC00289/C this specifies that it is a cast part no machining or further operation has been done on it whatsoever. The forging part have a “/SF” in the end after the part no which specifies that it is a forged part and has not undergone any other machining whatsoever. For example-3215T4/SF. When a certain operation is done the “/C” or “/SF” goes away and a “@” is added. Every operation results in an increase by ten. For example-18T5705@30 the “@30” means that three operations have been done on the part after the machine has come from the vendor after being cast. Hence it indirectly tells us the stage of the part. Upon completion the “@” is removed and we are left only with the main part number. Hence the part number tells us the status of the part and helps keep track of the part.
2) PART NAME
It gives the description of the part. Description tells us what the part is whether it is a pin, a pipe, or a gear etc. it gives the information of the part tells us its stage of machining if it is complete or a certain amount of machining has been done or it is just a fresh casting. It also gives a detailed description of the part for ex if it is a roller then if it is a vertical roller or a horizontal roller. It also sometimes gives the dimensions of the part for ex-BUSH RD 32X16 45C8 this gives the details of the dimensions of the job. It also tells us the stage of machining of the part for ex- BEVEL PINION (ROUGH TURN).
3) QUANTITY
It gives the total quantity of a particular part in the period 31/03/2014 to 1/04/2015.A particular component in a family which is most frequent in this period is chosen and pictorial inspection procedure for measuring critical dimensions (in castings, forgings, machined components, etc) is
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made. Frequency of a particular component also tells us which component is more important on the basis of high demand.
4) VENDOR CODE
Every vendor has their own code based on the name of the vendor. This helps categorise the vendors. All the transactions are made using the vendor code only. From the vendor code it is easy to extract complete information of the vendor. When we enter the vendor code in SAP then we automatically get all the details related to the vendor their full name, their address etc. It makes categorising the vendors easily. For example- the vendor code of JMT IS J04610and so on.
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3.4) LIST OF IMPORTANT FAMILIES:
TABLE 3.4.1: GEAR PLANETARY
Part Number Part Name Qty Vendor
3075002@110 GEAR;PLANETAR(W/O TEETH GRINDING) 1191 J04610
3075693@110 "GEAR;PLANETARY,SF" 187 J04610
3075723@110 "GEAR;PLANETARY,SF" 178 J04610
3075002@110 GEAR;PLANETAR(W/O TEETH GRINDING) 100 R24820
3075723@110 GEAR;PLANETARY,SF 20 R24820
3082148 GEAR PLANETARY 2227 R24820
3082155 GEAR PLANETARY 2384 R24820
3082517@80 GEAR;PLANETARY (HOBBING DONE) 1170 R24820
3084353 GEAR PLANETARY 2675 R24820
3053194@40 GEAR;PLANETARY(ROUGH TURN) 338 I24820
TD00740@20 GEAR (PLANETRY) ( ROUGH TURNED ) 40 I20780
TABLE 3.4.2: CARRIER
Part Number Part Name Qty Vendor
1009857 CARRIER 757 J04610
1010673 CARRIER 421 J04610
1011450 CARRIER 402 J04610
1022196 CARRIER 445 J04610
1022197 CARRIER 428 J04610
1022198 CARRIER 461 J04610
1025826 CARRIER 622 J04610
1025826/C CARRIER CASTING 8 J04610
TABLE 3.4.3: PIN
Part Number Part Name Qty Vendor
SE00062/SF PIN 658 M04890
SE00072/SF PIN 753 M04890
SE00074/SF PIN 392 M04890
SE00091/SF PIN 648 M04890
SE00092/SF PIN 739 M04890
SE00667/SF PIN 356 M04890
SE00979/SF PIN; SF 348 M04890
SE00980@100 PIN 363 M04890
SE00981@60 PIN 310 M04890
SE00982@60 PIN 307 M04890
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TABLE 3.4.4: TOOTH ADAPTER
Part Number Part Name Qty Vendor
TD05992 ADAPTER 1 1/2" ASSY 5 M04890
TB00704 TOOTH ADAPTER 290 M63200
TB00821 TOOTH ADAPTER(SIDE LOCKING TYPE) 64 M63200
TB01401 TOOTH ADAPTER 960 M63200
TC02162 TOOTH ADAPTER 40 M63200
TD08414 ADAPTER;TOOTH (HORIZONTAL LOCK) 70 M63200
TD08459 ADAPTER;TOOTH (HORIZONTAL LOCK) 139 M63200
TABLE 3.4.5: BOSS
Part Number Part Name Qty Vendor
4293526 BOSS 68 J04610
4385458 BOSS 97 J04610
2031101 BOSS(BOOM CENTER) 19 R24820
2057571 BOSS 48 R24820
2057732 BOSS(BOOM CENTER) 64 R24820
2033066 BOSS 41 I20780
4258101 BOSS 25 I24820
TABLE 3.4.6: BUSH
Part Number Part Name Qty Vendor
WE00599@70 BUSH; SEMI FINISHED 493 M04890
WE01086@40 BUSH ;SF 100 M04890
3040795@65 BUSHING 4 S5021M
3060476@40 BUSHING ;SF 317 S5021M
3094967@40 BUSHING ;SF 100 S5021M
4098099@40 BUSHING SF 141 S5021M
4099416@40 BUSHING;SF 55 S5021M
TABLE 3.4.7: SPROCKET
Part Number Part Name Qty Vendor
1010204@45 SPROCKET 1069 M63200
1010956@50 SPROCKET(W/O INDUCTION HARDENING) 9 M63200
1018740@15 SPROCKET; SF MACHINED 869 M63200
1022168@40 SPROCKET /SF 781 M63200
TB01070@40 SPROCKET MACHINED 12 M63200
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PART -2 PICTORIAL INSPECTION
PROCEDURES FOR
MEASURING CRITICAL
DIMENSIONS IN
CASTINGS,FORGING AND
MACHINED COMPONENTS
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4.1) INTRODUCTION
Critical dimensions of a particular component means the fitment dimension and tolerated dimension mentioned in drawing is of utmost importance, whereas dimensions which are not changing from semi-finished to finished stage can act as critical dimension. Few dimensions which are critical in drawing require special skill or method to check these dimensions. Therefore checking method is tabulated in pictorial format which are critical and requires special skill.
4.2) INSPECTION PROCEDURE
1) Families are formed on the basis of data downloaded from SAP for the period Apr’14 to Mar’15.
2) The component with the highest frequency in each family was taken to check.
3) The drawings of the component were studied and Critical dimensions are noted.
4) The critical dimensions are measured and photographs were taken simultaneously for making pictorial inspection flowchart.
5) Above mentioned Flow Chart was made for different families.
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4.3) PICTORIAL INSPECTION FLOW CHARTS
TABLE 4.3.1: BOOM CENTRE BOSS
Part Name Boom Centre Boss Date: 29/05/2015
Sl.No. Photograph Process
1 A hard paper is taken and a point is marked(O).
2 The radius to be measured is marked using a divider.
3 The radius profile is marked using the divider.
Checking Procedure of Boom Centre Boss
Checking Procedure of following dimension in boom centre boss:
1) To measure the radius.
30
RADIUS
Doc No: THCM'15-CF-01/a
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4A radius profile is to be cut using a pair of scissors along
the marked radius.
5 The radius profile is put on the boss and is measured.
30.06
Part Name Boom Centre Boss Date: 29/05/2015
Sl.No. Photograph Process
1The angle is measured using bevel protractor in the
shown way.
Checking Procedure of Boom Centre Boss
Checking Procedure of following dimension in boom centre boss:
1) To measure the angle.
22.5°
Doc No: THCM'15-CF-01/b
22.5°
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TABLE 4.3.2: ARM BOSS
Part Name Arm Boss Date: 29/05/2015
Sl.No. Photograph Process
1 Take a V-Block.
2 The boss is placed on the V-BLOCK.
3Both LOCATION 1 and LOCATION 2 is maintained at zero
using height gauge to ensure that the boss is at the same
level with respect to base/surface table.
4Then the angle is measured using bevel protractor as
shown in the figure.
Checking Procedure of Arm Boss
Checking Procedure of following dimension in arm boss:
1) To measure the angle.
0.00
16.4°
ANGLE
Doc No: THCM'15-CF-02/a
16.4°
LOCATION 1 LOCATION 2
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Part Name Arm Boss Date: 29/05/2015
Sl.No. Photograph Process
1The inner diameter is measured using vernier
calliper(inner jaws).
21)The base of the inner diameter is taken as 0.
2)Taking the inner radius length in the height gauge the
centre is marked.
3 Now the centre is taken as 0.
4The height gauge is brought down till the base/surface
table and distance is measured.
Checking Procedure of Arm Boss
Checking Procedure of following dimension in arm boss:
1) To measure the distance between the centre and base.
98.18
0.00
90.49
DISTANCE
0.00
49.09
Doc No: THCM'15-CF-02/b
90
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TABLE 4.3.3: BOOM FOOT BOSS
Part Name Boom Foot Boss Date: 29/05/2015
Sl.No. Photograph Process
1The distance is measured using vernier calliper(outer
jaws) by placing it on two extreme ends.
Checking Procedure of Boom Foot Boss
Checking Procedure of following dimension in boom foot boss:
1) To measure the distance between the opposite outer ends.
268.36
Doc No: THCM'15-CF-03/a
268
Part Name Boom Foot Boss Date: 29/05/2015
Sl.No. Photograph Process
1Tap diameter is measured from inside of boss using
vernier calliper(inner jaws).
Checking Procedure of Boom Foot Boss
Checking Procedure of following dimension in boom foot boss:
1) To measure the Tap diameter.
8.20
Doc No: THCM'15-CF-03/b
8
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Part Name Boom Foot Boss Date: 29/05/2015
Sl.No. Photograph Process
1
1)The boss should be kept in the position shown in the
photograph using Magnetic Block.
2)The perpendicularity is to be checked with respect to
base/surface table with the help of try square.
2The inner diameter is measured using vernier
calliper(inner jaws).
3 The base of the inner diameter is marked 0.
4Taking the inner radius in the height gauge,centre of the
boss is marked.The inner radius is taken as A.
Checking Procedure of Boom Foot Boss
Checking Procedure of following dimension in boom foot boss:
1)To measure distance between the centre and base of the boss.
114.96
0.00
57.48
Doc No: THCM'15-CF-03/c
109.5
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5Putting the vernier on the half line mark the thickness of
the boss is measured and is taken as B.
6 Therefore the distance is A+B.
B
DISTANCE
52.34
Part Name Boom Foot Boss Date: 29/05/2015
Sl.No. Photograph Process
1The angle is measured using bevel protractor in the
shown way.
Checking Procedure of Boom Foot Boss
Checking Procedure of following dimension in boom foot boss:
1)To measure the angle(6.8°).
6.8°
Doc No: THCM'15-CF-03/d
6.8°
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TABLE 4.3.4: BUSH
Part Name Bush Date: 30/05/2015
Sl.No. Photograph Process
1 A Bush is placed on a V-BLOCK.
2A dial gauge is taken and attached to the height gauge in
the following manner.
3Both the height gauge and dial gauge is to be marked 0
(as reference point) at the starting point of the
groove(just outside the groove).
Checking Procedure of following dimension in bush:
1)To measure the Groove Depth.
Checking Procedure of Bush
0.00
0.00
Doc No: THCM'15-CF-04/a
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4Now the dial gauge is to be placed at the lowest point of
the groove and it is to be pressed or released until the
pressure becomes 0.(same as the reference)
5The reading on the height gauge is noted and it gives the
groove depth.
0.00
0.00
1.22
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Part Name Bush Date: 30/05/2015
Sl.No. Photograph Process
1 A Bush is placed on a V-BLOCK.
2The width of the groove is measured using digital vernier
calliper(inner jaws).
Checking Procedure of Bush
Checking Procedure of following dimension in bush:
1)To measure the Groove Width.
6.77
Doc No: THCM'15-CF-04/b
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TABLE 4.3.5: CARRIER
Part Name Carrier Date: 28/05/2015
Sl.No. Photograph Process
1 Place the carrier on the V-Block.
2Check the prependicularity of the face with
the base/surface table.
3Maintain the hole on the same level using
height gauge with respect to base/surface
table.
Checking Procedure of Carrier
Checking Procedure of following dimension in carrier:
1) Angle between the pad centre and planetary bore.
0.00
0.00
ANGLE = 60°
Doc No: THCM'15-CF-05/a
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4Measure the hole diameter using vernier
calliper.
5 Taking zero at the base of the Hole.
6Marking to be done at half of the hole after
checking it with Vernier Calliper.
7
1)A proper reference point is marked on the
horizontal centre line of the bore.
2)Taking proper radius arcs are cut on both
sides of the bore and joined.
3)The line joining is extended to meet the
true centre of the carrier.
0.00
29.14
14.58
ARCS
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8
1)A line parallel to the base is drawn on the
pad of the carrier(as shown in the
photograph).
2)A proper reference point is marked on the
line.
3)Taking proper radius arcs are cut on both
the sides and joined to get the pad centre.
9The line is extended and it intersects the
previous vertical centre line.
10The angle between the pad centre and
planetary bore is found to be 60°
60°
Part Name Carrier Date: 28/05/2015
Checking Procedure of Carrier
Checking Procedure of following dimension in carrier:
1) Pitch Circle Diameter.
P.C.D
Doc No: THCM'15-CF-05/b
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Sl.No. Photograph Process
1The inner diameter is measured using vernier
calliper(inner jaws) and the distance is taken as
A.
2Distance between the inner diameter and the
base of the hole is measured and is taken as B.
3the hole diameter is measured.The radius of
the hole is taken as C.
4 Hence P.C.D is A+B+C.
91.57
34.40
29.14
A
B
P.C.D
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Part Name Carrier Date: 30/05/2015
Sl.No. Photograph Process
1 Take an outside micrometer.
2
It is calliberated with its master test piece.
For example-the micrometer in the figure
matches with the 0 line and is calliberated to
50 mm.
Checking Procedure of following dimension in Carrier:
1)To measure the bore diameter.
Checking Procedure of Carrier
50
BORE DIA
Doc No: THCM'15-CF-05/c
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3A bore gauge is taken and adjusted according
to the bore diameter to be measured.
4
The bore gauge is placed in the outside
micrometer and using the dial gauge it is
calliberated according to the bore
diameter.The arrow should coincide with the
0 of the dial gauge.This value gives the lower
limit of the bore diameter.
5
The bore gauge is placed inside the planetary
bore and the deviation in the dial gauge from
0 gives the range.Here it is 0.03.Hence the
bore diameter is the lower limit+maximum
deviation in the needle(range).Here it is
52.03.
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TABLE 4.3.6: CENTRE JOINT BODY
Part Name Centre Joint Body Date: 15/06/2015
Sl.No. Photograph Process
1The centre joint body is sectioned into two halves and
one half is taken and chalked for the purpose of marking
and measuring the groove height.
2Both the outer sides of the centre joint body is
calliberated to zero to ensure that it is completely
vertical.
3The casting reference is calliberated to zero using the
height gauge.
Checking Procedure of following dimension in Centre Joint Body:
1)To measure the groove height .
Checking Procedure of Centre Joint Body
0.00
0.00
Doc No: THCM'15-CF-06/a
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4The machining reference depth is taken and is marked
using the height gauge.
5The first groove height is measured(taking the casting
reference as the reference point).Similarly all the other
groove heights are measured according to the drawing.
101.02
75.01
Part Name Centre Joint Body Date: 15/06/2015
Sl.No. Photograph Process
1The machining reference is calliberated to zero using a
height gauge.
Checking Procedure of Centre Joint Body
Checking Procedure of following dimension in Centre Joint Body:
1)To measure the left out space after making the groove.
16
55
0.00
Doc No: THCM'15-CF-06/b
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2The height of the starting point of the groove from the
machining reference is taken in the height gauge and
marked.
31)The starting point of the groove is calliberated to zero.
2)The groove width(5) is taken from starting point of the
groove and marked using height gauge.
4
1)Then the end point of the groove is calliberated to
zero.
2)The left out space is then measured using height
gauge.Similarly all the other left out spaces are
measured.
16.00
0.004.96
0.00
5.30
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TABLE 4.3.7: GEAR PLANEATARY
Part Name Gear Planetary Date: 28/05/2015
Sl.No. Photograph Process
1The inner diameter is measured using vernier
calliper(inner jaws).
2
The root diameter = 106.60 is measured using vernier
calliper(outer jaws) by measuring distance between two
opposite ends.
REMARKS: This can only be measured if the number of
teeth is even or else it will be measured in CMM.
3
The tip diameter is measured using vernier calliper(outer
jaws) by measuring distance between two opposite
ends.
REMARKS: This can only be measured if the number of
teeth is even or else it will be measured in CMM.
Checking Procedure of following dimension in Gear Planetary:
1)To measure the Inner Diameter.
2)To measure the Root Diameter.
3)To measure the Tip Diameter.
Checking Procedure of Gear Planetary
41.41
134.30
106.63
INNER DIA
ROOT DIA
TIP DIA
Doc No: THCM'15-CF-07/a
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Part Name Gear Planetary Date: 28/05/2015
Sl.No. Photograph Process
1Take the base/surface table as reference and mark it 0
using the height gauge
2Measure the height at location 1 and take it as reference
for checking parallelity.
3
Measure the height at Location 2 and at Location 3
.There is a variation from 0.01 to 0.07.The difference
between the maximum and minimum values at two
different locations is called PARALLELITY(e.g:here it is
0.07).
Checking Procedure of Gear Planetary
Checking Procedure of following dimension in Gear Planetary:
1)To measure the parallelity.
0.00
63.77
63.78
63.84Location 2
Location 1
Location 3
Doc No: THCM'15-CF-07/b
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TABLE 4.3.8: PIN
Part Name Pin Date: 12/06/2015
Sl.No. Photograph Process
1 A BENCH CENTRE TABLE is to be used.
21)Clean the pin centre.
2)Place the pin between the chucks.
Checking Procedure of following dimension in Pin:
1)To measure the run out .
Checking Procedure of Pin
Doc No: THCM'15-CF-08
60 | P a g e
3Touching the dial gauge tip on the surface of the pin at a
fixed location and rotating the pin with hand and finding
out the minimum outer diameter.
4The minimum outer diameter is calliberated at 0 on the
dial gauge.
5
1)The pin is roatated keeping the dial gauge fixed and the
maximum deviation is noted.
2)The half of the maximum deviation from zero is the
run out of the pin.Here it is 0.02/2=0.01.
0.00
0.02
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TABLE 4.3.9: SPROCKET
Part Name Sprocket Date: 11/06/2015
Sl.No. Photograph Process
1 A sprocket is placed on a wooden plank.
2 The outer teeth profile is marked using a pen.
3The marking is checked using a try square to assure that
the marking done and outer dia match.
Checking Procedure of following dimension in Sprocket:
1)To measure the pitch distance .
Checking Procedure of Sprocket
216.5
Doc No: THCM'15-CF-09
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4 The inner dia profile is marked using a try square.
5The sprocket is removed from the plank and the inner
diameter is measured using a digital vernier
calliper(inner jaws).
6
Taking half the length of the inner diameter on the
vernier calliper the centre of the sprocket is marked by
cutting the arcs.The arcs are cut by placing the vernier at
two different positions.
7Taking the length of the pitch circle radius from the
centre a profile is marked.
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8The centre of the tooth tip is marked using a divider as
shown in the photograph.
9The centre of the alternate tip is also marked to measure
the pitch distance as shown on the top.
10The pitch distance is measured using a digital vernier
calliper(inner jaws).
216.5
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TABLE 4.3.10: TOOTH ADAPTER
Part Name Tooth Adapter Date: 12/06/2015
Sl.No. Photograph Process
1The tooth adapter is kept in a vertical position as shown
in the photograph with the help of magnetic V-Block.
2 The base/surface table is calliberated to zero.
3The height of the base of the hole is measured from both
the sides to ensure that the tooth adapter is completely
vertical.
Checking Procedure of following dimension in Tooth adapter:
1)To measure the width at the datum line .
Checking Procedure of Tooth Adapter
57.34
Doc No: THCM'15-CF-10/a
65 | P a g e
41)The hole diameter is marked.
2)The base of the hole is marked 0.
5Taking the hole radius on the height gauge the centre of
the hole is marked.
6
The depth of 39 is taken to mark datum line from
marked hole centre and is marked on all sides of the
tooth adapter using the height gauge.This point is named
as A.
7The width is measured at point A and as it is the required
fitment dimension..
0.00
Holeradius
39.00
A
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8 Now the point A is marked Zero.
9The height of 45 is taken to mark the next datum line
from point A and is marked on all sides of the tooth
adapter using the height gauge.This point is named as B.
10The width is measured at point B as it is the required
fitment dimension.
0.00
45.00
73.33
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Part Name Tooth Adapter Date: 12/06/2015
Sl.No. Photograph Process
1A tooth adapter is taken and tilted by the angle given in
the drawing.Here it is 10°.
2 The base of the hole is taken as 0.
Checking Procedure of Tooth Adapter
Checking Procedure of following dimension in Tooth adapter:
1)To measure the distance on both sides of the centre of the tooth adapter .
TILT BY 10°
0.00
53
Doc No: THCM'15-CF-10/b
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3Taking the hole radius on the height gauge the centre of
the tooth adapter is marked.
4 The centre is marked 0.
51)The distance from the centre to the base is measured.
2)The distance from the centre to the top is measured.
Holeradius
0.00
53.5
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TABLE 4.3.11: TOOTH POINT
Part Name Tooth Point Date: 15/06/2015
Sl.No. Photograph Process
1
The tooth point is kept in a vertical position as shown in
the photograph with the help of magnetic V-Block.The
magnetic block is locked on one side to make proper
adjustments to assure that the block is vertical.
2Both the left and right sides are calliberated to zero to
ensure that the tooth point is completely vertical.
3The holes on the front side and back side are calliberated
to zero to ensure that the tooth point is at 90° with
respect to base/surface table.
Checking Procedure of following dimension in Tooth Point:
1)To measure the width at the datum line .
Checking Procedure of Tooth Point
0.00
0.00
Doc No: THCM'15-CF-11/a
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4The V-Block is locked on both sides after calliberation to
avoid movement of tooth adapter.
5
1)The hole diameter is measured.
2)Thebase of the hole is calliberated to zero.
3)Taking the hole radius the centre is marked using a
height gauge.
6The inner portion of the tooth point is chalked for
marking.
7The centre of the hole is marked zero on the height
gauge.
8
The depth of 43 is taken to mark datum line from
marked hole centre and is marked on all sides of the
tooth adapter using the height gauge.This point is named
as A.
26.94
13.47
0.00
A
71 | P a g e
9The width is measured at point A with the help of a
divider and as it is the required fitment dimension.
10 The point A is calliberated to zero.
11The height of 50 is taken to mark the next datum line
from point A and is marked on all sides of the tooth
adapter using the height gauge.This point is named as B.
12The width is measured at point B with the help of a
divider and as it is the required fitment dimension.
58.33
0.00
81.61
B
72 | P a g e
Part Name Tooth Point Date: 15/06/2015
Sl.No. Photograph Process
1The inner jaws of the vernier calliper is placed at the
intersection of the straight line and curve and the width
is measured.
Checking Procedure of Tooth Point
Checking Procedure of following dimension in Tooth Point:
1)To measure the width at the intersection of the straight line and curve of the tooth point .
Doc No: THCM'15-CF-11/b
86.65
73 | P a g e
PART -3 CRITICAL DIMENSIONS
CHECK SHEETS FOR
DIFFERENT FAMILIES OF
INCOMING
COMPONENTS AT
CASTING/FORGING
STORES
74 | P a g e
5.1) INTRODUCTION
The drawings were studied of different families made in PART-1 and the critical
dimensions were marked as shown in the check sheets below. These Critical
dimensions of a particular component were chosen on the basis of the fitment
dimension and tolerated dimension mentioned in drawing which is of utmost
importance, whereas dimensions which are not changing from semi-finished to
finished stage can act as critical dimension.
The contents of the table are:
1) Parameter: These are the different nomenclature of critical dimensions
which are to be measured (Eg: Height, Thickness, Angle, Width etc.)
2) Specification: These are the actual dimensions mentioned in the
drawings which are to be checked using proper checking instruments.
3) Tolerance: This gives the dimensional range of the mentioned
specification depends on whether the component is casting, forging or
machined. The tolerance of the machined components is lesser compared to
casting. For eg: if the specification of a particular component is 75 and
tolerance is ± 0.30 then the range of the specification is from 74.70 to 75.30.
4) Checking Instrument: It tells us about the instrument from which the
dimension of a particular specification is to be measured. The instrument is
chosen based on the tolerance of a particular specification.
Least count of instrument used should be less than or equal to 1/10th of the
given tolerance range. For eg:
a) If tolerance is ± 0.50mm, then the range of tolerance is 1mm, therefore
it can be checked with the instrument having maximum least count of
0.1mm.
b) If tolerance is ± 0.020mm, then the range of tolerance is 0.040mm,
therefore it can be checked with the instrument having maximum least
count of 0.004mm.
75 | P a g e
5.2) CHECK SHEETS
TABLE 5.2.1: BOSS
PART DESCRIPTION Doc No. Rev Date Rev No.
Boom Centre Boss THCM'15-CF/CD-01 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 75.00+2.10
-1.10Digital Height Gauge
2 Dia 74.00+2.10
-1.10Digital Vernier Calliper
3 Dia 152.00-0.10
-0.30Digital Vernier Calliper
4 Height 65.00+2.10
-1.10Digital Height Gauge
5 Height 97.00+2.10
-1.10Digital Height Gauge
6 Thickness 14.00+1.50
-0.70Digital Vernier Calliper
7 Angle 22.5° ± 0.5° Bevel Protractor
8 Dia 70.00+2.10
-1.10Digital Vernier Calliper
9 Outer Dia 290.00+3.00
-1.50Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Boom Centre Boss
Checked ByRemarks
Approved By
Part No.
3037936
1
2
3
4
567
8
9
76 | P a g e
TABLE 5.2.2: BUSH
PART DESCRIPTION Doc No. Rev Date Rev No.
Bush THCM'15-CF/CD-02 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 123.000.00
-0.50Digital Height Gauge
2 Inner Dia 109.50+0.10
+0.00Digital Vernier Calliper
3 Outer Dia 131.00+0.10
+0.00Digital Vernier Calliper
4 Groove Width 7.00 ± 1.00 Digital Vernier Calliper
5 Depth 1.30 ± 0.30 Digital Height Gauge
Accepted
Rejected
Inspection Report Of Bush
Checked ByRemarks
Approved By
Part No.
3060476
1
2 3
4
5
77 | P a g e
TABLE 5.2.3: CARRIER
PART DESCRIPTION Doc No. Rev Date Rev No.
Carrier THCM'15-CF/CD-03 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Dia 159.500.00
-0.10Digital Vernier Calliper
2 Dia 154.000.00
-0.20Digital Vernier Calliper
3 Dia 140.00 ± 2.50 Digital Vernier Calliper
4 Dia 70.00 ± 2.20 Digital Vernier Calliper
5 Angle 30° 0.5° Bevel Protractor
6 Height 40.00 ± 1.80 Digital Height Gauge
7 Height 50.00 ± 2.00 Digital Height Gauge
8 Thickness 20.50+0.40
0.00Digital Vernier Calliper
9 Height 95.00+0.25
-0.75Digital Height Gauge
10 Height 65.40+0.50
+0.60Digital Height Gauge
11 Height 154.50 ± 2.50 Digital Height Gauge
12 Dia 40.00+0.040
+0.000Dial Bore Gauge
13 Dia 203.48 ± 2.80 Digital Vernier Calliper
14 Outer Dia 272.00 ± 3.10 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Carrier
Checked ByRemarks
Approved By
Part No.
1009857
1 2
3
4
5
6
7 89
10
11
12
13
14
78 | P a g e
TABLE 5.2.4: CENTRE JOINT BODY
PART DESCRIPTION Doc No. Rev Date Rev No.
Centre Joint Body THCM'15-CF/CD-04 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 223 ± 2.80 Digital Height Gauge
2 Height 200 ± 0.20 Digital Height Gauge
3 Height 191 ± 0.20 Digital Height Gauge
4 Height 166 ± 0.20 Digital Height Gauge
5 Height 141 ± 0.20 Digital Height Gauge
6 Height 116 ± 0.20 Digital Height Gauge
7 Height 91 ± 0.20 Digital Height Gauge
8 Height 66 ± 0.20 Digital Height Gauge
9 Height 41 ± 0.20 Digital Height Gauge
10 Length 25 ± 1.00 Digital Height Gauge
11 Length 50 ± 1.00 Digital Height Gauge
12 Length 75 ± 1.00 Digital Height Gauge
13 Length 101 ± 1.00 Digital Height Gauge
14 Dia 90+0.090
+0.090CMM
15 Dia 90+0.180
-0.140CMM
16 Dia 122+2.00
-0.00Digital Vernier Calliper
17 Width 106 ± 0.20 Digital Vernier Calliper
18 Width 130 ± 2.50 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Centre Joint Body
Checked ByRemarks
Approved By
Part No.
SB00040
18
17
16
15
14
1
23 4
5
6 7 89
1011
12
13
79 | P a g e
TABLE 5.2.5: GEAR PLANETARY
PART DESCRIPTION Doc No. Rev Date Rev No.
Gear Planetary THCM'15-CF/CD-05 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Inner Dia 57.00+0.031
+0.009Digital Vernier Calliper
2 Thickness 31.500.00
-0.25Digital Vernier Calliper
4 Outer Dia 117.000.00
-0.30Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Gear Planetary
Checked ByRemarks
Approved By
Part No.
3075693@110
1
2
3
80 | P a g e
TABLE 5.2.6: PIN
PART DESCRIPTION Doc No. Rev Date Rev No.
Pin THCM'15-CF/CD-06 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 102.00 ± 0.50 Digital Height Gauge
2 Height 62.00 ± 0.30Digital Height Gauge &
Digital Vernier Calliper
3 Height 289.00 ± 0.80Digital Height Gauge &
Digital Vernier Calliper
4 Height 320.00 ± 0.80 Digital Height Gauge
5 Dia 71.00-0.10
-0.17Outside Micrometer
6 Thickness 40.00 ± 0.30 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Pin
Checked ByRemarks
Approved By
Part No.
WD00005
1 2
3
4
5
6
81 | P a g e
TABLE 5.2.7: SPROCKET
PART DESCRIPTION Doc No. Rev Date Rev No.
Sprocket THCM'15-CF/CD-07 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Thickness 70.00+1.00
-3.00Digital Height Gauge
2 Radius R10 ± 1.40 Radius Gauge
3 Radius R55 ± 2.00 Radius Gauge
4 Radius R10 ± 1.40 Radius Gauge
5 Radius R55 ± 2.00 Radius Gauge
6 Thickness 35.00 ± 1.80 Digital Vernier Calliper
7 Angle 25° 0.5° Bevel Protractor
8 Angle 25° 0.5° Bevel Protractor
9 Dia 419.00+0.30
-0.02Digital Vernier Calliper
10 Thickness 21.00 ± 1.60 Digital Vernier Calliper
11 Hole Dia 16.00-22.00+0.30
-0.20Digital Vernier Calliper
12 P.C.D 464.00 ± 3.50 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Sprocket
Checked ByRemarks
Approved By
Part No.
1018740
1
2
3
4
5 6
7 8
10
9
11
82 | P a g e
TABLE 5.2.8: TOOTH ADAPTER
PART DESCRIPTION Doc No. Rev Date Rev No.
Tooth Adapter THCM'15-CF/CD-08 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Width 72.70 ± 2.20 Digital Vernier Calliper
2 Width 50.70 ± 2.00 Digital Vernier Calliper
3 Width 35.90 ± 1.80 Digital Vernier Calliper
4 Hole Dia 20.00 ± 1.60 Digital Vernier Calliper
5 Height 30.00 ± 1.80 Digital Height Gauge
6 Height 45.00 ± 1.20 Digital Height Gauge
7 Height 102.00 ± 1.00 Digital Height Gauge
8 Height 39.00 ± 0.50 Digital Height Gauge
9 Length 41.00+2.00
0.00Digital Vernier Calliper
10 Width 60.70 ± 1.20 Digital Vernier Calliper
11 Width 60.70 ± 1.20 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Tooth Adapter
Checked ByRemarks
Approved By
Part No.
TB01401
1
2
3 4
8
7
5 6
9
10 11
83 | P a g e
TABLE 5.2.9: TOOTH POINT
PART DESCRIPTION Doc No. Rev Date Rev No.
Tooth Point THCM'15-CF/CD-09 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Width 60.00 ± 2.00 Digital Vernier Calliper
2 Width 52.00 ± 2.00 Digital Vernier Calliper
3 Length 50.00 ± 0.25 Digital Vernier Calliper
4 Length 50.00 ± 2.00 Digital Vernier Calliper
5 Height 80.00 ± 2.20 Digital Height Gauge
6 Thickness 21.00+2.00
-0.00Digital Vernier Calliper
7 Height 286.00 ± 3.10 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Tooth Point
Checked ByRemarks
Approved By
Part No.
TD09575
1
2
3
4
5
6
7
84 | P a g e
TABLE 5.2.10: BEARING
PART DESCRIPTION Doc No. Rev Date Rev No.
Bearing THCM'15-CF/CD-10 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Dia 75.00+0.034
-0.030Inside Micrometer
2 Height 65.00 ± 0.10 Digital Height Gauge
3 Height 14.50 ± 0.20 Digital Height Gauge
4 Height 13.25 ± 0.10 Digital Height Gauge
5 Height 42.00+0.50
-1.00Digital Height Gauge
6 Height 26.00 ± 1.80 Digital Height Gauge
7 Dia 127.00+0.10
-0.20Digital Vernier Calliper
8 Dia 142.00+2.00
-1.00Digital Vernier Calliper
9 Outer Dia 160.00+2.00
-1.00Digital Vernier Calliper
10 Drill Dia 10.90 ± 1.50 Digital Vernier Calliper
11 Drill Dia 16.00 ± 1.50 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Bearing
Checked ByRemarks
Approved By
Part No.
1026776
1
2
3
4
6 5
9
8
7
10 11
85 | P a g e
TABLE 5.2.11: COVER
PART DESCRIPTION Doc No. Rev Date Rev No.
Cover THCM'15-CF/CD-11 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Outer Dia 345.00 ± 0.80 Digital Vernier Calliper
2 Dia 332.00+0.20
0.00Digital Vernier Calliper
3 Dia 288.00 ± 0.80 Digital Vernier Calliper
4 Dia 20.00 ± 0.021 Digital Vernier Calliper
5 Thickness 5.00 ± 0.20 Digital Height Gauge
6 Length 27.00 ± 0.30 Digital Height Gauge
7 Thickness 9.00 ± 0.20 Digital Height Gauge
8 Thickness 11.00 ± 0.20 Digital Height Gauge
9 Dia 288.00 ± 0.80 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Cover
Checked ByRemarks
Approved By
Part No.
2034833
1
2 3
4
5 6
7
8
9
86 | P a g e
TABLE 5.2.12: DRUM
PART DESCRIPTION Doc No. Rev Date Rev No.
Drum THCM'15-CF/CD-12 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 143.00+0.50
0.00Digital Height Gauge
2 Dia 349.00+0.80
0.00Digital Vernier Calliper
3 Dia 290.01-0.003
-0.054CMM
4 Height 59.75 ±0.10 Digital Height Gauge
5 Height 12.50 ±1.50 Digital Height Gauge
6 Height 22.00 ±1.60 Digital Height Gauge
7 Height 97.00 ±2.20 Digital Height Gauge
8 Dia 412.00+0.073
+0.010CMM
9 Dia 481.000.000
-0.012CMM
10 Dia 568.00 ±3.50 Digital Vernier Calliper
11 Hole Dia 16.00 ±1.50 Digital Vernier Calliper
12 P.C.D 447.00 ±3.50 Digital Vernier Calliper
13 Hole Dia 20.00 ±1.60 Digital Vernier Calliper
14 Dia 332.00 ± 0.20 Digital Vernier Calliper
15 Depth 19.50 ± 0.20 Digital Height Gauge
16 Depth 2.50 ± 0.20 Digital Height Gauge
Accepted
Rejected
Inspection Report Of Drum
Checked ByRemarks
Approved By
Part No.
1022179
1
2
3 4 5 6
7
8
9
10
11
13
14
15 16
87 | P a g e
TABLE 5.2.13: GEAR SUN
PART DESCRIPTION Doc No. Rev Date Rev No.
Gear Sun THCM'15-CF/CD-13 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Dia 68.00+0.045
+0.020Dial Bore gauge
2 Parallelity 0.05 N.A. Digital Height Gauge
3 Dia 106.000.00
-0.30Digital Vernier Calliper
4 Outer Dia 112.000.00
0.20Digital Vernier Calliper
5 Thickness 92.30-0.10
-0.40Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Gear Sun
Checked ByRemarks
Approved By
Part No.
3082156@60
1
2
3 4
5
88 | P a g e
TABLE 5.2.14: IDLER
PART DESCRIPTION Doc No. Rev Date Rev No.
Idler THCM'15-CF/CD-14 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 63.00+0.00
-0.50Digital Height Gauge
2 Dia 36.00+0.025
+0.00Dial Bore Guage
3 Outer Dia 302.00+2.00
-1.00Digital Vernier Calliper
4 Thickness 31.00-0.50
-1.00Digital Height Gauge
5 Thickness 26.00 ± 1.80 Digital Height Gauge
6 Dia 72.00 ± 0.10 Digital Vernier Calliper
7 Step 13.00 ± 0.10 Digital Height Gauge
8 Step 13.50 ± 1.50 Digital Height Gauge
9 Dia 61.70 ± 0.10 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Idler
Checked ByRemarks
Approved By
Part No.
SD00247
1
6
2
3
5
4 7
8
9
89 | P a g e
TABLE 5.2.15: NUT
PART DESCRIPTION Doc No. Rev Date Rev No.
Nut THCM'15-CF/CD-15 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Thickness 29.00 ± 0.30 Digital Height Gauge
2 Thickness 24.00+0.30
-0.50Digital Height Gauge
3 Outer Dia 175.00 ± 2.80 Digital Vernier Calliper
4 Dia 128.00 ± 2.50 Digital Vernier Calliper
5 Thickness 15.00 ± 0.20 Digital Height Gauge
6 Dia 97.00 ± 2.20 Digital Vernier Calliper
7 Step 5.50 ± 0.20 Digital Height Gauge
8 P.C.D. 151.00 ± 0.50 Digital Vernier Calliper
Accepted
Rejected
Inspection Report Of Nut
Checked ByRemarks
Approved By
Part No.
3099830
1
2
4
3
6
5
7
8
90 | P a g e
TABLE 5.2.16: SHAFT
PART DESCRIPTION Doc No. Rev Date Rev No.
Shaft THCM'15-CF/CD-16 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Dia 29.40 ± 1.80 Digital Vernier Calliper
2 Dia 32.70 0.00
-0.20Digital Vernier Calliper
3 Dia 39.50+1.30
-1.80Digital Vernier Calliper
4 Outer Dia 109.600.00
-0.20Digital Vernier Calliper
5 Thickness 16.80 ± 0.20 Digital Height Gauge
6 Length 236.00 ± 2.80 Digital Height Gauge
7 Length 53.00 ± 2.00 Digital Height Gauge
Accepted
Rejected
Inspection Report Of Shaft
Checked ByRemarks
Approved By
Part No.
2049585@50
1
2 3
4
5
6
7
91 | P a g e
TABLE 5.2.17: SHROUD
PART DESCRIPTION Doc No. Rev Date Rev No.
Shroud THCM'15-CF/CD-17 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Length 70.00 ± 1.10 Vernier Calliper
2 Length 17.00 ± 0.85 Digital Height Gauge
3 Thickness 48.00 ± 1.40 Vernier Calliper
4 Thickness 15.00 ±1.10 Vernier Calliper
5 Thickness 20.00 ±1.20 Vernier Calliper
6 Length 125.00 ± 1.80 Vernier Calliper
Accepted
Rejected
Inspection Report Of Shroud
Checked ByRemarks
Approved By
Part No.
4257065
1
2
3
4
5
6
92 | P a g e
TABLE 5.2.18: SLEEVE
PART DESCRIPTION Doc No. Rev Date Rev No.
Sleeve THCM'15-CF/CD-18 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Thickness 24.50 ± 1.60 Digital Height Gauge
2 Outer Diameter 252.70/252.60 ± 0.05 Digital Vernier Calliper
3 Thickness 35.000.00
-0.25Digital Vernier Calliper
4 Dia 148.00 ± 0.10 Digital Vernier Calliper
5 Thickness 24.00 ± 1.60 Digital Height Gauge
6 Thickness 14.50 ± 1.50 Digital Height Gauge
Accepted
Rejected
Inspection Report Of Sleeve
Checked ByRemarks
Approved By
Part No.
3078670@50
1
2
3 5
4 6
93 | P a g e
TABLE 5.2.19: SPINDLE
PART DESCRIPTION Doc No. Rev Date Rev No.
Spindle THCM'15-CF/CD-19 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Height 299.50+0.20
0.00Digital Height Gauge
2 Height 197.00 ± 0.20 Digital Height Gauge
3 Height 181.00 ± 0.20 Digital Height Gauge
4 Height 169.00 ± 0.20 Digital Height Gauge
5 Height 156.00 ± 0.20 Digital Height Gauge
6 Height 144.00 ± 0.20 Digital Height Gauge
7 Height 131.00 ± 0.20 Digital Height Gauge
8 Height 119.00 ± 0.20 Digital Height Gauge
9 Height 106.00 ± 0.20 Digital Height Gauge
10 Height 94.00 ± 0.20 Digital Height Gauge
11 Height 81.00 ± 0.20 Digital Height Gauge
12 Height 69.00 ± 0.20 Digital Height Gauge
Inspection Report Of Spindle
Part No.
SB00090@50
1
2 3 4
5 6 7 8 9
10
11
12
13
14
15
16
17
23
22
21
20
19
18
24
94 | P a g e
Sl.No Parameter Specification Tolerance Checking Instrument Observation
13 Height 56.00 ± 0.20 Digital Height Gauge
14 Height 44.00 ± 0.20 Digital Height Gauge
15 Height 31.00 ± 0.20 Digital Height Gauge
16 Thickness 91.00 ± 0.50 Digital Height Gauge
17 Thickness 50.00 ± 0.30 Digital Height Gauge
18 Dia 67.000.00
-0.30Outside Micrometer
19 Dia 70.000.00
-0.10Outside Micrometer
20 Dia 90.50/90.60 ± 0.05 Outside Micrometer
21 Dia 89.50 ± 0.50 Outside Micrometer
22 Dia 100.60/100.50 ± 0.05 Outside Micrometer
23 Dia 108.00 ± 0.50 Outside Micrometer
24 Thickness 10.00+0.50
+0.20Digital Vernier Calliper
Accepted
Rejected
Checked ByRemarks
Approved By
95 | P a g e
TABLE 5.2.20: YOKE
PART DESCRIPTION Doc No. Rev Date Rev No.
Yoke THCM'15-CF/CD-20 22-06-2015 0
Sl.No Parameter Specification Tolerance Checking Instrument Observation
1 Dia 7.60+0.10
-0.20Digital Vernier Calliper
2 Dia 4.10 ± 0.20 Digital Vernier Calliper
3 Height 15.20 ± 0.10 Digital Height Gauge
4 Height 12.50 ±0.20 Digital Height Gauge
5 Height 10.00+0.15
0.00Digital Height Gauge
6 Dia 40.00 ±0.30 Digital Vernier Calliper
7 Height 50.70 ± 0.30 Digital Height Gauge
8 Height 15.20 ± 0.10 Digital Height Gauge
Accepted
Rejected
Inspection Report Of Yoke
Checked ByRemarks
Approved By
Part No.
1017138
1
2
3
4
5
6
7
8
96 | P a g e
SUMMARY:
To enhance the knowledge management of QA casting and forging store by documenting the inspection and drawing reading skills of the department members. The following work has been done to accomplish the same:
1) Families of similar components were formed after categorising the parts from the data downloaded for 7 vendors which accounts for 83.62 % of incoming components at casting & forging store for last financial year(2014-15).
2) The component with the highest frequency in each family was taken to inspect and pictorial procedure was tabulated for dimensions which are critical and requires special skills for inspection.
3) Check sheets were prepared for one part of a particular family to narrow down the critical dimensions for daily incoming inspection.
4) The pictorial inspection procedure and Check sheets can be followed for all the similar members of the family.