Lean Manufacturing (5-S Implementation) &

Improvement of Valve Casting

Seminar for the submission of INDUSTRIAL PROJECT

DEPARTMENT MECHANICAL ENGINEERINGGURU NANAK DEV ENGINEERING COLLEGE,LUDHIANA.

Submitted By:-Jastinder Pal Singh 1144839B.Tech Mechanical (2011-15)

Content

• Industry Introduction• Project Undertaken• Project (1) 5-S Implementation

Methodology Literature SurveyAction PlanResults

• Project (2) Improving Mild Steel CastingMethodologyLiterature SurveyProposed Precautions & SuggestionsResults

• ANSYS Software Training

References

INDUSTRY INTRODUCTION

Hi-Tech Castings

• Hi-Tech Casting was established in 1995 in Ludhiana by Mr. Kanwaljit

Singh with the objective to supply high quality customized casting

solutions.

• Hi Tech Castings have been regarded as the pioneer in the field of

manufacturing & supply of C.I, M.S Castings in various grades. Casting

weight ranges from 1 Kg to 800 kg.

• Products includes automobile component, machinery component, thermal

plant components etc.

Project (1st) - 5-S Implementation

• Aim of the Project:The aim of the project is to apply 5-S concept in Company.

• Methodology:1. Understanding the 5-S concept.2. Analyzing the process flow.3. Study of plant and prepare action plan.4. Training the workers for 5-S and working.5. Eliminating unnecessary movement & suggesting new method.

• Literature Survey: 5-S is a simple tool for organizing your workplace in a clean,

efficient and safe manner to enhance your productivity, visual management and to ensure the introduction of standardized working.

Project Undertaken

Five Tools Of 5-S Concept

1. Seiri: (sorting): Sort out important & unimportant things & put the unimportant ones away

from workplace.2. Seiton: (Systematic Arrangement): Keep the things on the prescribed place in continuous & regular pattern.3. Seiso: (Spic & Span): Maintain the cleanliness of the work place regularly.4. Seiketsu: (Standardization): Always work on the standard prescribed pattern.5. Shitsuke : (Self - Discipline) : Maintain self - discipline.

Need of 5-S Concept In Company:1. Overproduction 2. Waiting3. Transport 4. Motion5. Over-processing 6. Defects

Main Points of Action Plan:

Removing unwanted parts (objects) Properly organizing the parts

Maintain cleanliness Preventive Maintainers

Proper identification of areas Proper guidelines for work

Results

• Visual feedback

• Availability

• Proper identifications

• Continuous flow

• Increase in production rate

• Quality

• Reduce space requirement

Project (2nd) – Improving Mild Steel Casting

Aim of the Project:• To provide an introduction to the causes and remedies of the main

solidification defects in castings• Diagnose the major defects in castings and propose methods of preventing

them.

Research Methodology:• Literature Survey• Analyzing the process flow.• Study of various defects problem in MS casting.• Eliminating reasons of defects & suggesting new method.

Literature Survey(a) Gas Porosity

This can be due to following three causes:• Gas precipitation: Gas held in solution in the molten metal can be precipitated

as the metal solidifies, simply as a result of the reduced solubility on freezing.

• Gas coming from cores: The sand binders used to make the moulds and cores often break down when in contact with the molten metal and the gaseous decomposition products can force their way into the solidifying metal, leading to defects which are normally known as 'blows'.

• Air Entrapment: If the mould is filled under very poor conditions, air can be entrained in the metal stream and then trapped as the metal solidifies.

(b) Shrinkage PorosityThe second type of defect that is sub-divided into macroporosity and microporosity.

• Macroporosity: The best known form of macroporosity is the 'pipe' formed as a simple ingot of a short freezing range alloy solidifies.

• Microporosity: This is particularly a problem in long freezing range alloys. These conditions create an extensive and uniform pasty zone.

(c) SLAG PROBLEM

Main causes of slag formation:

• Melting Methods

• Ladle

• Alloy Loss

• Desulfurization

• Refractory problem

Proposed Precautions & Suggestions

1. Precautions during refractive paint process:• Not properly painting of mould with refractive paint, produce pin holes on

surface and gas porosity in casting. Thus following points during apply of refractive paint to mould should take in consideration:

i. Proper mixing of paint before use is must.

ii. Use paint gun to paint mould.

iii. Apply paint in thin layer and constant on

all the mould.

iv. Never paint the mould from that place

where direct contact of molten metal is not to be there.

v. Paint should be so it can-not get removed on rubbing with hand.

vi. Properly heat the mould after paint applied.

2. Precautions during mould closing:• During mould closing always rember these points:

i. Never close mould more than 3 hours before pouring.

ii. Never paint inside mould after closing(even

spure and risers should paint before closing).

iii. Never heat mould after closing.

iv. Always use plain surface (or single plate)

below mould, to prevent mould breakdown

from bottom during pouring.

v. Ensure about weight kept on mould should double than casting weight to

prevent mould lift.

3. Proposal for moulding process improvement:• Use blind sleeve for blind risers:

In case of moulding sometimes there is need of blind riser in mould. But we use other methods instead. Disadvantages of this are:

a. Use of open sleeve for blind riser: Use of open sleeve for blind riser leads following problems:i) Fast cooling of metal in riser as compared to the calculated meth-ding. With fast cooling there maybe shrinkage.ii) Mould sand above open sleeve of blind riser get breakdown and lead to slag in casting.

b. Change in method: i) Sometimes we change the method for moulding that have maximum of riser as open riser. May be thismethod is not so effective for soundness of casting.ii) This may lead to low material yield for casting.

4. Proposal for pouring improvement:• Use of bottom ladle: Use of bottom ladle have following advantages:

i) Reduction in slag pouring problem with molten metal in mould cavity.ii) Maximum of molten metal in ladle can poured in mould easily.

5. Change in riser and feeding meth-ding:Change in feeding & rising method, modulus method instead of

shape factor method.

Shape factor method Modulus method

• Less yield as riser pad is used • More yield no riser pad is used

• Proper trained worker should their • Semi-skilled worker can easily get the point

• Chill size is to be calculation is must • Chill size can be easily estimated

Result

• Surface pin hole problem shot out• Shrinkage and Gas porosity in valve flanges get overcome• Material yield increased

SOFTWARE TRAINING ATCADD CENTRE, PATHANKOT

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›ANSYS Workbench is a computer aided finite element modelling (FEM) and finite element analysis(FEA) tool. ›User can generate 3-D and FEA models, perform analysis and generate results of

analysis.›ANSYS Workbench enables to combine the stand-alone analysis system into a

project and to manage the project workflow.› It ties together the entire simulation process, guiding the user through even

complex multiphysics analyses with drag-and-drop simplicity. › It consist of Highly-automated and physics-aware meshing.› Complete analysis system that guides the user start-to-finish through an analysis.› Complex project schematics can be saved for re-use.› Integrated, analysis-focused geometry modeling, repair and simplification via

ANSYS Design modeler.

INTRODUCTION TO ANSYS

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LIST OF ANALYSES IN ANSYS›Linear Buckling›Modal›Static Structural›Steady State Thermal›Transient Thermal

INDUSTRIAL APPLICATION OF ANSYS

›Analysis of Connecting Rod for Automobile Industry›Transient Thermal Analysis of a Piston›Thermal Stress in a Cylinder or Uniform Temperature Change›Buckling of a Pinned-Pinned Column or a Built-Up Structure›Steady State Thermal Analysis of a Heat Sink›Natural Frequencies of Motor Cover or any Assembly›Static Structural Analysis of Cylindrical Pressure Vessel, Bracket and

Clevis Assembly

MESHING ANALYSIS

NATURAL FREQUENCIES OF CONNECTING ROD

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REFRENCES

• As discussed in http/www.alueurope.eu/talat/lectures/3207.pdf, Solidification Defects in Castings.

• As discussed in http://www.afe.polsl.pl/index.php/en/2781/geometrical-modulus-of-a-casting-and-its-influence-on-solidification-process.pdf, Geometrical modulus of a casting and its influence on solidification process.

• Sharma, P.C. (2014), “The Casting Process,” Production Technology, pp. 573-211.