final ppt 2007
TRANSCRIPT
A project on,“CENTRIFUGE MACHINE FOR
REMOVING EXCESS ZINC AFTER GALVANIZING PROCESS”
ByKansara Nachiket R.
Gujar Sayali R.Mali Chetankumar D.
Bhosale Shital S. Under The Guidance Of
Prof. A. D. Bagawade
INTRODUCTIONCorrosion protection of carbon steel
component is achieved by Metallic coating. Zinc is usually chosen for reason of
economics and reliable.Zinc coating is done by an electroplating
process and by hot dip galvanizing. In hot dip galvanizing Corrosion protection is
proportional to the coating thickness, i.e. the thicker the coating the longer the service life.
What is hot dip galvanizing?
Fig. Galvanizing process
PROBLEM STATEMENT•After the Hot Dip Galvanizing of the Materials like Nuts, Bolts and Washers, zinc gets stuck-up in between their threaded portions.
•Necessity to remove this excess Zinc to achieve better Quality of uniform & smooth coating of the small parts.
•This Extra zinc is presently removed by using Grinders, Flat & Round rough files and by Hammering on it.
To perform above operations following are the Disadvantages.1. Manual Work harmful to the face & eyes of the Operators. 2. Time consuming and reduces the output.3. Reduced the Production and Productivity beyond the Target. 4. Due to extra Coating, Zinc consumption increases.
BASE STAND FLANGE
PARTS
ROTATING CAGE OUTER CONICAL DRUM
BUCKET
OUTER STATIONARY DRUM
ROTATING CAGE
FLANGE
SUPPORTING BEARING
BASE STAND
MOTOR
ARRANGEMENT OF PARTS
ASSEMBLY OF CENTRIFUGAL MACHINE
CENTRIFUGE MACHINE
WITHOUT USING CENTRIFUGAL MACHINE
USING CENTRIFUGAL MACHINE
COMPARISON OF TWO PARTS
BEFORE NOW
EXCESS ZINC COLLECTED AFTER MACHINING
RESULTSSr.
No.
Parameters Foundation
Bolt
1 Black weight of single part (Kg) 0.964
2 Galvanized weight of single part (Kg) 1.02184
3 Total no. of parts in the bucket 731
4 Black weight of all parts (Kg) 704.684
5 Galvanized Weight of all parts (Kg) 746.96
6 Total amount of zinc required for coating of all
parts in Bucket (Kg)
42.276
Sr.
No.
Parameter (For Foundation Bolt) With
Centrifuge
Machine
Without
Centrifuge
Machine
a. Weight of zinc collected after manual
removing of all parts in one bucket
(Kg)
17.61 7.037
b. Cost of zinc collected after manual
removing of all parts in one bucket
(Rs.140 / 1 Kg)
2466 985
c. Weight of zinc collected for 1 ton of
parts (Kg.)
25 10
d. Cost of zinc saved/ ton of parts (Rs.) 3500 1400
e. Cost of zinc required for coating of
1ton of parts
4900 7000
Sr. No.
Parameter Without Centrifuge Machine
With Centrifuge Machine
1 Production/ shift (Kg.) 80 500
2 No. of shifts required/ton 12.5 2
3 Manpower/ shift 4 2
4 Manpower/ton 50 4
5 Manpower cost/ton (Rs.) 12500 1000
Manpower Cost
Total Cost SavedSr.
No.
Parameter Without
Centrifuge
Machine
With
Centrifuge
Machine
1 Cost of zinc required/ ton
of parts (Rs.)
7000 4900
2 Manpower cost/ton (Rs.) 12500 1000
Total Cost (Rs.) 19500 5900
Hence, by using Centrifuge Machine we can save, =19500-5900 =13600 Rs. /ton
COST ESTIMATIONParameter Cost (Rs.)
Raw material cost 26514
Machining cost 3778
Motor cost
Bearings (6206z)
(4 No.s)
16000
1250
Total cost 47542
ADVANTAGESSimple operation Automatic operation Optimum cleaning conditions Little space requiredNo Harm to face and eyes of the
Operator. Less Time consuming and increases the
output. Improve the Production Quality and
Productivity. Better Quality of uniform & smooth
coating
DisadvantagesCentrifuge Machine can only be used for continuous production.
It is used only for smaller parts like Foundation bolts, Bolts, Nuts, Washers etc.
Manual Loading and unloading.
CONCLUSION Large number of disadvantages with present
system used for removing excess zinc have been obsolete by implementing new centrifuge machine. By using this machine we can obtain better finish and quality of galvanized parts. The use of centrifuge machine can reduce the manpower cost with increase in production rate.
The amount of zinc recovered after a single spin in centrifuge machine is 1.75 % to 2.5% of total amount of zinc required for coating. Thus this recovered zinc can be reuse.
In the industries where continuous production and galvanizing of small is takes place, the centrifuge machine is the better option.
Future ScopeAutomization of Machine
Using of Variable speed motor
Arrangements
THANK YOU!