semi automatic forging with induction technology
TRANSCRIPT
INTRODUCTION TO THE
PROJECT
One of the sole purpose of Mechanical Engineering is to:
Develop and optimize various manufacturing processes & developingnew and more economically viable manufacturing processes.
We have incorporated various techniques of CAPP (Computer AidedProcess Planning ). One such vital and very much trending tool is LeanManufacturing process
PROBLEM STATEMENT
• What are the main drawbacks of traditional forging techniques?
• Obsolete furnace design using fossil fuel to heat hardly up to 900 c but has efficiency of about 30 %
• High fuel consumption rate decrease the profitability.
• Inconsistent and non uniform heating.
TRADITIONAL FURNACES• Non green process.• Waste disposal and furnace
maintenance.
INDUCTION HEATING - THE LEAN
GREEN ALTERNATIVE
AIM OF THE PROJECT
• By implementation of induction technology
• Decreasing lead time of production
• Optimized consistency
• Maximized productivity
• Improved product quality
• Environmentally sound
• Reduced energy consumption
“SEMI AUTOMATIC FORGING WITH
INDUCTION TECHNOLOGY”
The entire project can be classified intothree sub chapters and will be discussedone after another as follows:
• Induction heating system
• Semi automatic Forging press system
• Automatic Robotic Handling system
INDUCTION HEATING SYSTEM
HYDRAULI
C PRESS
FORGING
UNIT
ROBOTIC MANIPULATOR
INDUCTION HEATING
APPLICATION
INDUCTION FURNACE
INDUCTION WELDING
• INDUCTION BRAZING
INDUCTION SEALING
HEAT TREATMENT
APPLICATION CONTINUED
• Forging industry application.• Automotive and aerospace Industry Solutions• Power Generation Industry Solutions• Oil & Gas Industry Solutions• Food Industry Heating Solutions• Cable and Wire Heating Solutions• Medical Device Manufacturing Solutions
THEORY
• Important Factors to Consider• METAL OR PLASTIC• MAGNETIC OR NONMAGNETIC• THICK OR THIN• RESISTIVITY• Inductor Design• Power Supply Capacity• Degree of Temperature Change Required
IMPORTANT FACTORS TO BE CONSIDERED
Material Final temp.°C Efficiency
Carbon steel 1250 0.65
Carbon steel 700 0.80
Stainless steel 1250 0.60
Brass 800 0.50
Copper 900 0.40
Aluminum 500 0.40
efficiency of heat transfer in induction heating
FREQUENCY SELECTION FOR GIVEN DIAMETER AND TEMPERATUE
• (1) From vacuum tube oscillator and electronic generator
• (2) From spark-gap generator• (3) From motor-generator set• (4) From solid-state inverters
TYPES OF POWER SYSTEM
IGBT is the most suitable to be used as a power source.
GOVERNING EQUATION
SKIN DEPTH AT GIVEN FREQUENCY OF CERTAIN MATERIAL
SIMULATION RESULTS
INDUCTOR DESIGN
• Material : copper• No . Of turns :6• Diameter of rod: 3 mm• Applied frequency : 160 khz• Temp of work piece : 900 degree C• Electrical rating:220v ,10 A• Time of heating: 30sec• Power consumption : 2200 KW
Before calculating our energy requirements we first need to know:
• • The type of material (steel, copper, brass, etc.)• • Work piece dimensions• • Desired hourly production• • Desired final temperature
VIDEO ON HEATING
Hydraulic press forging system
• What is Press Forging?
definition:• The shaping of metal between dies by mechanical or
hydraulic pressure. Usually this is accomplished with a
single work stroke of the press for each die station.
Working principle of press
FORGING FORCE
DIE DESIGN
DESIGN
All dimensions are in inch
Robotic manipulator
JOINT
ACTUATOR
Controller
ROBOTIC ARM DESIGN
ROBOT Geometry
FANUC code for the desired movement
• SPEED 60 • JOINT A1= 80.67 A2= -59.22 A3= 81.58 A4= -0.15 A5= -19.51 A6= 5.76 • GRIPPER OPEN • JOINT A1= 80.67 A2= -50.15 A3= 72.51 A4= -0.15 A5= -19.51 A6= 5.76 • GRIPPER CLOSE • SPEED 90• JOINT A1= 2.15 A2= -63.5 A3= 75.52 A4= -0.15 A5= -0.97 A6= 5.75• JOINT A1= 2.15 A2= -55.29 A3= 67.31 A4= -0.15 A5= -4.64 A6= 5.76• WAIT 30000• JOINT A1= 2.15 A2= -72.34 A3= 84.36 A4= -0.15 A5= -4.63 A6= 5.76• WAIT 60000• SPEED 100• JOINT A1= 79.78 A2= -64.23 A3= 80.56 A4= -0.15 A5= -4.64 A6= 5.76• JOINT A1= 79.78 A2= -59.32 A3= 75.65 A4= -0.15 A5= 62.19 A6= 5.76• WAIT 20000• GRIPPER OPEN• WAIT 1000• HOME_ALL
• Video
THEORITICAL ECONOMIC ANALYSIS:
Parameters Conventional forging Process:
COST Induction forging process:
COST
Production time.
90 min ----------- 35 min --------
Lead time : More Less
Fuel consumption :
8-10 Kg coal + fuel oil+Auxiliarymachinery cost
Rs 4@ RS 400/ ton coal+ RS 5 + Rs 6 =Rs 15
Electricity=1.16 KWh + .54 Kwh
Rs 8.50@ Rs 7/ kWh
Polluting gases: Present Non green Absent Green
Accuracy : 30% ------------ 80% -----------
Efficiency : 40% ------------ 75% ------------
Rate of production:
LOW HIGH
For making 10 square section from round bar by a single worker we adopted two procedure for a study :
PROBLEMS WE MAY ENCOUNTER
• High initial cost of implementation.
• Critical electronic solid state circuit .
• Resonance matching required to get desired heating effect.
• Skilled work force .
FUTURE SCOPE
• It is a new and emerging field in modern manufacturing technology.
• Ample scope of research and development with the coil design , die design , and implementation of automation.
• Portability can be increased.
• Response to different material can be studied.
• Experimental validation of certain hypothetical statements can be verified.