calander thickness measurement and analysis.pdf
TRANSCRIPT
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Presented by:
ALAWATHTHAGE G.C. (RU/E/2009/004)
KULATHUNGA H.G.G. (RU/E/2009/095)
RATHNAYAKA R.M.P.P.K. (RU/E/2009/148)
CALENDAR THICKNESS MEASUREMENT
and
ANALYSIS
SECOND PROGRESS
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PRESENTATION OUTLINE
CALENDARING PROCESS
INTRODUCTION TO THE PROBLEM
LITERATURE REVIEW
MEASURING AND ANALYSIS OF CALENDAR LAYER THICKNESS
MEASURING AND ANALYSIS OF CALENDAR ROLLER SURFACE
CONCLUSIONS OF INVESTIGATIONS
REASONS FOR ISSUE
AMOUNT OF MATERIAL WASTE
SOLUTION
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Why Calendaring in Tyre Manufacturing?
For making inner liner & calendar layer
What is Calendaring Process?
Calendaring process
CALENDARING PROCESS IN TYRE
MANUFACTURING
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INTRODUCTION TO THE PROBLEM
Research Problem
Cross Section of Calendar Layer
There is no any scientific investigation carried out to related to the
issue
project targets to find a most suitable solution and improve the
productivity, working efficiency as well as saving of valuable material
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similar type of issue in metal strip manufacturing, but in that case,
metal strip thickness is varying along length of the metal strip.
Research is done by T. Widmaier, T. Salmela, P. Kuosmanen, J.
Juhanko, P. Karha and J. Uusima.
Try to understand the phenomena behind the rolling force variations
seen in the rolling force measurements. The aim was to reduce the periodic rolling force variation and to
study how this affects the thickness variations of the steel strip.
LITERATURE REVIEW
Thickness Variation Along Length of Metal Strip
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RESEARCH METHODOLOGY
1. Measuring the calendar thickness.
2. Data analysis and calendar surface mapping.
3. Measuring the calendar roller surface variation.
4. Data analysis and calendar roller surface mapping.
5. Impact of the side cutters to the issue.
6. Effect of tension variation and sagging of the calendar layer.
7. Cost estimation for the material waste.
8. Finding a most affordable solution to solve the issue.
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RESEARCH METHODOLOGY
Specifications of Obtained a inner liner
Thickness Width Length2mm 1500mm 4250mm
Preparations for the Taking Measurements
Decided to measure the thickness of the calendar from the distanceof 5cm.
To achieve that firstly we divide the layer in widthwise in to 5cm
partitions and then lengthwise.
Calendar Thickness Measurement, Data Analysis and
Sur face Mapping
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RESEARCH METHODOLOGY
5cm square divisions Measuring the Layer Thickness
Thickness Gauge
Used Microsoft excel and MATLAB software
packages for Data Analysis and Surface Mapping
Calendar Thickness Measurement, Data Analysis and
Sur face Mapping
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RESEARCH METHODOLOGY
Calendar roller sur face var iation Measurement, Data
Analysis and Sur face Mapping
A special methodology for roller surface measurement.
Measuring process
Marking Measuring Coordinates on the roller and reference edge
Paper Strip with Coordinates pasted on the roller
Reference Edge with Coordinates System
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RESEARCH METHODOLOGY
Calendar roller sur face var iation Measurement, Data
Analysis and Sur face Mapping
Measuring process
The Reference edge mounted to the machine using brackets.
Adjust the distance by moving the reference edge through the slots.
Measure the distance between reference edge & roller surface by
using two feeler gauges sets.
Reference Edge Mounting to the MachineFeeler Gauge Set
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Used Microsoft excel and MATLAB software packages for Data
Analysis and Surface Mapping
RESEARCH METHODOLOGY
Calendar roller sur face var iation Measurement, Data
Analysis and Sur face Mapping
Impact of the side cutters to the issue
visually inspected the surfaces of both calendar rollers.
Compare the surfaces.
Effect of tension var iation and sagging of the calendar layer
Based on the pattern of thickness variation.
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RESEARCH METHODOLOGY
Cost estimation for the mater ial waste
Measure the weight of a sample.
Calculate the density.
Calculate the excess material per unit length.
Estimate the annual loss.
F inding a most affordable solution to solve the issue
Changing the order of roller location.
Roller grinding or refurbishment.
Improvement for cutter mounting.
Roller replacement.
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OBSERVATIONS, RESULTS & DISCUSSION
0
5
10
15
20
25
30
0
5
10
15
20
25
30
1.5
2
2.5
3
WIDTH
SurfacePlot ofCalendarLayer First Measurement
LENGTH
T
HICKNESS(mm)
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
0
5
10
15
20
25
30
0
5
10
15
20
25
30
1.5
2
2.5
3
WIDTH
SurfacePlot ofCalendarLayerSecondMeasurement
LENGTH
THICKNESS(mm)
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
0
5
10
15
20
25
30
0
5
10
15
20
25
30
1.5
2
2.5
3
WIDTH
SurfacePlot ofCalendarLayerThirdMeasurement
LENGTH
THICKNESS(mm)
1.9
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Surface Plots of Calendar Layer
Calendar Thickness Measurement, Data Analysis and
Sur face Mapping
Similar pattern of variation along the width.
Thickness vary from 1.9mm to 2.7mm.
No any considerable variation along the length
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OBSERVATIONS, RESULTS & DISCUSSION
Calendar roller sur face var iation Measurement, Data
Analysis and Sur face Mapping
Significant variation along the length of the calendar roller
Roller Surface Plot
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Defected Areas of Calendar
Layer
Defected Areas of Calendar
Roller
Surface Plot of Calendar Layer Surface Plot of Calendar Roller
OBSERVATIONS, RESULTS & DISCUSSION
Comparison of resul ts
Defected Areas are similar in both calendar surface and roller surface
variation.
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Difference of Roller Surface and Calendar thickness
OBSERVATIONS, RESULTS & DISCUSSION
Comparison of resul ts
Difference of the calendar roller surface and the average calendar
thickness is having a linear relationship.
It is proven that the issue is occurred due to the surface variation of
the roller surface
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Damaged area ofroller
Side Cutter
Direct Contact of Cutter Roller
Roller Contact
with cutters
Roller without
Contact cutters
Impact of Cutters
OBSERVATIONS, RESULTS & DISCUSSION
Impact of the side cutters to the issue
The roller which is directly contact with cutters are severely damaged
while other one in good condition.
Effect of tension variation and sagging of the calendar layer
No variation along the length of the calendar layer.
No impact of tension variation or calendar layer sagging.
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It is average loss per day 580kg and average cost of it is 350Rs.
580*350 = Rs. 203000
OBSERVATIONS, RESULTS & DISCUSSION
Cost estimation for the mater ial waste
Density of compound 1207.79Kgm^(-3)Actual Weight in 1m length 3.648Kg
Expected Weight in 1m length 3.503Kg
Material Waste 0.145Kg
Think About loss
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1. Changing the order of roller location Three roll mill machine.
only two rollers are using.
replace the defected roller with non used roller.
2. Roller grinding or refurbishment
cost is around Rs.85000 to Rs.145000.
3. Roller replacement with a new one
Cost is around $2000 to $5000 must imported.
4. Improvement for cutter mounting.
Only above 1 or 2 or3 solutions are not enough.
To avoid the issue permanently need to avoid direct contact of cutters and roller.
Modification is compulsory with a above solution.
OBSERVATIONS, RESULTS & DISCUSSION
F inding a most affordable solution to solve the issue
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OBSERVATIONS, RESULTS & DISCUSSION
Modif ication for M achine
New roller
Modified Design
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Project targets to measure and analysis of the calendar thickness
variation
Identified the amount of variation and the pattern of the variation
Studied and investigate the impact of the most related facts to the
issue of the thickness variation
To avoid that issue it is suggesting the following solutions
Changing the order of roller location
Roller grinding or refurbishment
Roller replacement with a new one
Modification for cutting process
Conclusion
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