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RIM MANUFACTURING PROCESS FLOW

Prepared by:-Atul Kaushal

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Valve Hole Piercing& Coining

Butt Weld

Finishing

RIM MANUFACTURING PROCESS FLOW

De-coiler Leveler Cut To Length BatchMarking

Coiling Flattening ButtWelding

TrimmingRollingSlittingRe-RoundingBandCooling

Flaring

R F-2 RF -3

EdgeConditioning

Expander Air LeakTesting

InspectionR F -1

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Coil Loader

Process:- Coil loading in the de-coiler

Process Objective:-To load the coil tofeed in CTL

Key points :-

1.Check the Telecopy defect in the coil

2.Check the Burr at the edge

3.Coil acceptance status, Batch code ,Heat no./

De-coiler:-

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Process:- Straitening of the loaded

CoilProcess Objective:-In this leveler withhelp of the these all roller do straight thecoil.

Key points :-

1.Check the entry roller and exit rollerthickness as per requirement or not

2.Guide roller must be in center

3.Both guide roller(entry and exit) must bein parallel

Leveler:-

Leveler

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Process:- Cut the coil as on strip

Process Objective:-In this operation withhelp of the cutter cut the coil as on strip.

Key points :-

1.Check the cutter plate angle is ok or not

2.Check the left side of the all guide rollermust be in center

CUT TO LENGTH :-

Cut to length(CTL)

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Process:- Punch the batch marking on

stripProcess Objective:-In this operation withhelp of the marking insert we doing batchcode marking on strip.eg. AAA AMW 4.5JX13H2 RCC016 A92999A-Year code ,A-Month code ,A-1st heat codeA-Asia , M-Motor, W-Works4.5-Rim width in inch , J-Profile code13-Rim OD in inch, H2-Hump TwoR-Rim , C- Car, C-CodeA92999-TAC no.(Test Approval Certificate)

Key points :-

1.Check the marking as visual must be ok &free form insert mark.

BATCH MARKING :-

Batch marking

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Process:- Converting strip in to coil

form

Process Objective:-In this operation withhelp of the rollers we coil the strip.

Key points :-

1.Butt joint both face must be in parallel.

2.Check the outer/inner both side coilermark .

coiling:-

coiling

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Process:- Flattening on butt joint area

Process Objective:-To get good welding &good finishing in trimming operation.

Key points :-

1.Check the flattening must be proper andfree form tool mark .

FLATTENING :-

Flattening

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Process:- Butt welding on butt joint area

Process Objective:- To joint the both coilend.

Key points :-

1.Check the Butt joint both side should beok and free form defect (Heeling, Fusing,overlap etc.)

BUTT WELDING :-

Butt welding

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Process:-Trim on the butt joint .

Process Objective:-To remove theunwanted material which is available on thebutt weld.

Key points :-

1.Check the cutting must be proper and noany shallow flash cutting, deep flashcutting, overlap etc.

TRIMMING:-

Trimming

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Process:-Rolling on the butt weld

Process Objective:-In this operation withhelp of the two roller(upper& bottom) dorolling on the butt weld.

Key points :-

1.Rolling platform must be clean by wirebrush

2.Both roller free form dent mark

3.Check the rolling mark, deep rolling markshould not be there

4.Check at the time of operation bothroller is rotating or not

rolling:-

Rolling

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Process:-Trim the butt joint edge

Process Objective:-To trim the unwantedmaterial which is available on both sidebutt joint edge.

Key points :-

1.Check the surface must be free formburr & tool mark.

slitting:-

Slitting

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Process:-Re-rounding the butt joint area

Process Objective:- To do the flaringoperation near butt joint area roundnessis required.

Key points :-

1.Check the surface must be free formtool mark.

Re-rounding:-

Re-rounding

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Process:-Cooling of the band

Process Objective:-The band should be getcooled to the level of bare hand touchfeel.

Key points :-

1.Butt joint must be free form defect..(Heeling, Flash cutting, Overlap , Deepdent, Block mark, Necking etc)

Band cooling:-

Band cooling

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Process:- remove the burr which is

available on the butt weld.Process Objective:-To increase the flaringtool life(Burr can damage the flaring tool).

Key points :-

1.Burr should be clean properly & check thetool rolling mark etc

Edge conditioning:-

Edge conditioning

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Process:-Preforming operation of the rim

Process Objective:- Preforming operationas well as the butt welding testing.

Key points :-

1.Check the scoring mark & burr on bothside.

flaring:-

Flaring

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Process:-First stage of rim profile

makingProcess Objective:-To support the 3rd rollformer to get thePrint dimension

Key points :-

1.Check the Scuffing, rolling mark & burron both side.

Roll former-1:-

R.F-1

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Process:-Second stage of rim profile

makingProcess Objective:-To support the 3rd rollformer to get the Print dimension

Key points :-

1.Check the Scuffing, rolling mark & burron both side.

Roll forming-2:-

R.F-2

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Process:-Third stage of rim profile

makingProcess Objective:- To support theexpander to get the Print dimension

Key points :-

1.Check the Scuffing, rolling mark & burron both side.

Roll forming-3:-

R.F-3

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Process:-Last stage of rim profile making

Process Objective:-With help of expandertool, expand the complete rim profile asper print.

Key points :-

1.Check the rim must be free form burr &expander tool mark .

EXPANDER:-

EXPANDER

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Process:-Valve hole for air filling in the

tyre.Process Objective:-For air filling in thetyre valve hole piercing is required & toremoved the burr from the valve holecoining operation required.

Key points :-

1.Check the valve hole dia ok or not.

2.Valve hole must be free form burr &toolmark .

VALVE HOLE PIERCING & COINING:-

VHP&VHC

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Process:-Checking operation of the butt

weld.

Process Objective:-To check the butt weldany pin hole or hair line crack.

Key points :-

1.Check the air pressure as per controlPlan.

2.Check the machine is giving result ok or

not, for that check with air leak samplerim this must be show Rej.

3.Check the punch must be in center of thewell area.

Air leak test:-

Air leak testing m/c

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Process:-Final finishing on the rim

Process Objective:-Cleaning the butt weldedge ,burr & mark.

Key points :-

1.Check the butt weld finishing ,mark &buffer mark.

BUTT WELD FINISHING:-

BUTT WELD FINISHING

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Process:-Rim visual inspection

Process Objective:-Rim visual inspectionby Quality like dent mark ,butt welddefect, rolling mark, hair line crack etc.

Key points :-

1.Ensure the inspector having knowledgeabout rim defect & appearance inspectionstandard.

2.He must be aware about MARU-A, safety& critical characteristics of rim.

RIM INSPECTION:-

INSPECTION AREA

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THANK YOU

THANK YOU