How automatic gear box works
Classification
rear wheel drive
Front wheel drive
Introduction
PROJECT INDEX1.SELECTION OF PROJECT
2.DEFINITION OF PROJECT
3.ANALYSIS OF PROBLEM
4.CAUSE AND EFFECT ANALYSIS
5.DEVELOPMENT OF SOLUTION
6.REGULAR IMPLEMENTATION
7.CONCLUSION
SELECTION OF PROJECT TO REDUCE BORE UNCLEAR REJECTIONS IN
SMALL END OF THE CONNECTING ROD
PART NAME:CONNECTING ROD
COMPONENT:BACR13
DEFINITION OF CONNECTING ROD A rod connecting two moving parts in a mechanism
, especially that between piston and the crank shaft in an engine or pump.
BIG END
STEM
SMALL END
ANALYSIS OF PROBLEMRAW MATERIAL SPECIFICATION :
TEST METHOD=158811-1998
EQUIPMENT=OPTICAL EMISSION SPECTROMETER
CHEMICAL COMPOSITON
ELEMENT MIN. MAX.
CO 0.19 0.22
Mn 0.6 0.85
Si 0.15 0.35
S _ 0.03
P _ 0.03
Cr 0.9 1.2
Ni _ 0.2
Mo 0.17 0.3
Al _ 0.025
HARDNESS=230BHN Max.
BENDING THICKNESS=40microns Max.
ANALYSIS OF PROBLEMPARAMETERS TO BE MAINTAINED IN CONNECTING ROD:
PITCH DISTANCE
PERPENDICULARITY OR SQUARENESS
OVALITY
SURFACE FINISH
WALL THICKNESS
BIG END TAPER , OVALITY , BORE UNCLEAR
SMALL END TAPER , OVALITY , BORE UNCLEAR
SURFACE FINISH , PERPENDICULARITY , PITCH DISTANCE
DEFINITION OF PROBLEM SETTING OBJECTIVES
P-PRODUCTIVITY TO BE IMPROVED
Q-REJECTION PERCENTAGE TO BE REDUCED
C-OPERATIONAL COST TO BE REDUCED
D-ON TIME DELIVERY TO BE ACHIVED
GOAL SETTING
ACTUAL
TARGET
BORE UNCLEAR REJECTION IN 3 MONTHS
PROCESS FLOWCHART OF CONNECTING ROD
RAW
MATERIALFORGING
INWARD
INSPECTION
SMALL END
DRILLING
BIG END
ROUGH
BORING AND
CHAMFERING
INDUCTION
SOFTENING
SHOT
BLSTINGTEMPERING
CASE
HARDNING
OIL HOLE
DRILLING
2ND
SIDE
CHAMFERING
SYMMETRY
INSP.AND
CORRECTION
FINISH
GRINDING
BOTH SIDES
BIG
END&SMALL
END HARD
BORING
OIL HOLE
DEBURGRING
SMALL END
CHAMFERINGBIG END
HONNING
BIG END BORE
INSPECTION
SMALL END
BORE
INSPECTION
VISUAL
INSPECTION
CD,BEND&TWI
ST
INSPECTION&
CORRECTION
CLEANINGSMALL END
HONNING
BIG END
MARKING
SAMPLING
INSPECTIONPACKIMG
BAJAJ AUTO
LTD.
SMALL END DRILLING
SANSERA VERTICAL MACHINING(SVM)
SANSERA HORIZONTAL DRILLING MACHINING(SHD)
DRILLING OF OIL HOLE DONE HERE FOR OIL FLOW
CASE HARDENING
TEMPERING
SHOT BLASTING
INDUCTION SOFTNING
SYMMETRY CORRECTION
DIAL GAUGE
DOUBLE DISC GRINDING
FACE GRINDING DONE HERE FOR BOTH FACES OF CONNECTING ROD
BIG END BORINGSMALL END BORING
.
SANSERA FINE BORING MACHINE
FINISHED FINE HONING FOR BIG END & SMALL END
VERTICAL HONING MACHINE
WASHING MACHINEREMOVAL OF OIL AND WATER FROM THE
COMPONENT SURFACE
BENDING TEST-8micronsTWISTING TEST-12micronsCENTRE TEST-250 to 350mmSMALL END BORE DIA. CHECKINGBIG END BORE DIA. CHECKINGVISUAL INSPECTIONDISPATCH
ALL THE PROBABLE CAUSES ARE LISTED BELOW
MACHINE MEASUREMENT
MATERIALMETHODMAN
FISH BONE DIAGRAM
MACHINE
FLOAT PAD MISMATCHARM SCREW OVERTIGHTCENTRE HEIGHT POINT PROBLEMIMPROPER INSERTLOCATOR PROBLEMINCORRECT FIXTURE
MEASUREMENT
WALL THICKNESS VARIATION DIAMETER VARIATION PITCH DISTANCE VARIATIONMATERIAL SPECIFICATIONS
MAN
UNSKILLED OPERATORLACK OF EXPERIENCELAZYNESSLACK OF CONCENTRATIONURGENCY
METHOD
UNCONVENTIONAL METHODINCORRECT TOOL SELECTIONIMPROPER PROGRAMMINGFLOT PAD MISMATCH
TRAIL SHEET
FIXTURE CALIBRATION REPORT
Through trials we have concluded that unclear occurs during boring and honing operations
actual CAUSES FOR UNCLeaR Float pad mismatch of the work piece Arm screw over tight Variation in Centre distance Power failure problem Smaller end arm tool problem Locator problem Incorrect component loading Incorrect fixture Butting , improper resting of work piece (The piece get crossed
or work piece move sideways) Offset setting changes
SUGGESTION TO REDUCE UNCLEAR
Arm screw should be properly tightened, otherwise component lifts
There should be frequent supply of power, otherwise taper, step lines and unclear occurs
Insert should be changed within 150 in number, otherwise undersize occurs
If insert is changed NT system should be controlled properly
After face grinding symmetry must be checked once again Operators should be well trained
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