magna m a g n a d i g i t e c h i n d i a p r i v a t e l i m i t e d steel fabricattion to ductile...

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d

STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION


PROJECT NAME : CHARGE AIR PIPE

SCOPE : To design and convert the present fabricated Charge Air Pipe to Ductile Iron Casting

USED IN : Tier II Locomotive Engine


1. To fabricate one component, it requires to assemble more than 40 components.

2. Ensuring the welding strength in all areas is a constraint3. Extensive fixture required to weld so that to meet the Dimension

accuracy.4. Each sub component will be considered as a fresh setting piece For

machining.5. Excessive Time consuming for welding and machining6. Since it has 40 sub components material property to be ensured

for all parts.

Constraints in Fabrication




1. The material property should meet both form , fit and assembly function

2. The casting should pass radiographic quality ASTM E446 Level II

3. The casting should pass 100% leak test to ensure there is no leakage for both water and air media.

6bar for water passage area for 5 minutes and

4.5bar for air passage area for 5 minutes

Key areas Identified by MagnaD




4. Wall thickness variation should be within 1.5mm (total tolerance) to the entire length (952.0mm)

5. During machining, to ensure the dimensions are well within specified limit.

Face parallelism within 0.2mm (length 940.00mm)

All holes to be within positional tolerance of 0.4mm in total and 0.1mm for one side.

6. Casting and machining feasibility.

Key areas Identified by MagnaD – cont.




1. Preparation of 3D model for discussion and to get ideas from various departments.(APQP)-Brain Storming

2. Preparation of casting model.

3. Pattern, core box, assembly design and 3D model preparation.

4. Casting model used to freeze the methoding design through simulation software.

5. Machining fixture design.

6. Leak test fixture design.

7. Dimension inspection check sheet.

Various stages of projects




This 3D model is fully parametric so that it can be easily get updated based on the suggestions from user departments without affecting the final customer specification.

Total weight of the casting 186kgs (410lbs)

Overall size 400x600x952mm (15.75x23.62x37.48inch).

3D model preparation for final casting




From the casting model best possible parting line for pattern and core box finalized.

All necessary drafts and fillets added in the casting area.

Proper core locks provided to avoid wall thickness variation.

Machining references also considered during pattern and core box design to ensure the casting to machined dimensions.

Pattern and core box Model




Pattern Model.Top Pattern

Core print

Bottom Pattern

Sand collector

Core print lock




Core box Model.

Core-1

Core-2

Core-3 Core Box bottom

Core Box Top

Core Box Loose piece




Casting methoding for pouring also finalized with the help of simulation software.

By this we are able to provide the best feeding solution to meet the x-ray quality ASTM –E446 Level II

Casting methoding design




Final component From all the effort the final component comes all right in the first

shot.

Final assembly Model

Final assembly Casting

2820mm

111.0inch




Advantages to Customer Total cost saving per component – 33%

Total time saved – 50%

Single point contact for entire assembly

Reduction in transportation time




STEEL FABRICATTION TO STEEL CASTING CONVERSIONSTEEL FABRICATTION TO STEEL CASTING CONVERSION

PROJECT NAME : MAGNET FRAME

SCOPE : To design and convert the present fabricated Magnet frame to Steel Casting


Varies steps

First we have made a 3D model of fully machined fabricated one and from there we have started identifying small components.

Due to section thickness variation we have spitted the parts into two.

To compare the casting behavior first we have analyzed the fabricated part and then our casting part. From the results we fine tuned our casting to meet the requirement.



Magnet frame Fabricated Part of Magnet frame steel Casting

Meshing of Magnet Frame


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