# process re validation

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MAHAVIR CASTERS PLANT -3 IMPROVEMENT PROJECT MAHAVIR DIE CASTERS PLANT - III

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MAHAVIR CASTERS PLANT -3

IMPROVEMENT PROJECT

MAHAVIR DIE CASTERS PLANT - III

MAHAVIR CASTERS PLANT -3

PROJECT THEME

Process Revalidation For Grip Casting By

Bharat [email protected]

MAHAVIR DIE CASTERS PLANT - III

MAHAVIR CASTERS PLANT -3

• Process should be as per aesthetic part.• Help to reduce soldering.• Increase plunger life.• Increase die life.• Increase machine life.• Reduce flow porosity.

MAHAVIR DIE CASTERS PLANT - III

Why we need to revalidate?

MAHAVIR DIE CASTERS PLANT -III

How?

• As we know aesthetic casting doesn't need casting pressure up to 800 kg/cm^2 .• Casting appearance should be good with respect to non filling, crack, & flow porosity.• As per pq^2 diagram

P=Ct*Vg^2

Here,P= pressure on the plunger face:,Ct= composite discharge coefficient,Vg= velocity of the liquid metal at the Cavity gate.

MAHAVIR DIE CASTERS PLANT -III

From above equation, we can say that,If reduce gate velocity then pressure on plunger face will reduce with same ratio.

Let’s take an example: Machine: 400TPart: Grip KTRPlunger dia: 70mmInjection piston head dia: 101mmStatus: AestheticN2 charging pressure in Intensification accumulator: 90kg/cm2(It should be 7 kg/cm2 less than minimum Required intensification charging pressure.)Pressure build up time:200msNow from above data,We have to set casting pressure according to aesthetic part Cp= Ip*(d/D)^2Cp=Casting pressureIp= Intensification pressured= Plunger diaD=Injection piston head dia

MAHAVIR DIE CASTERS PLANT -III

So from above eq’n

Cp=Cp*(d/D)^2

For same machine and die “d” & “D” constant Now eq’n become

Cp ὰ Ip (Casting pressure directly prepositional to intensification)Means as I increase Ip, Cp will directly increase with same ratioAndIp increase when intensification charging pressure will increase

MAHAVIR DIE CASTERS PLANT -III

So now I conclude as we have to minimize intensification charging pressure as decrease to intensification pressure as decrease casting pressure which isnot required as much as technical parts.

MAHAVIR DIE CASTERS PLANT -III

Let’s talk about pressure build up time:Pressure build up time is a time taken to achieve max intensification from intensification charging pressure.

Pressure build up time

MAHAVIR DIE CASTERS PLANT -III

• To understand how its work lets take example:pressure build up time control by a valve as shown in image on which no’s of turn Available.N=No’s of turnV=volume of oilv= velocity of oilA=area through which oil has to passt= time taken by volume of oil to flow.Q=discharge

As we know, Q=V/t…………(1)Q=Av………………………………(2)From 1 & 2V/t=Av

(t= V/Av)Now from above eq’nPressure build up time will increase asVolume of oil increase .This volume will increase by opening this valve.

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nsifi

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lve

MAHAVIR DIE CASTERS PLANT -III

• So we can reduce plunger velocity. • Reduce intensification charging pressure.• Increase intensification valve turn.• And to avoid shrinkage we can increase intensification phase speed & reduce Intensification charging pressure as shown in screen shot image.

MAHAVIR DIE CASTERS PLANT -III

MAHAVIR DIE CASTERS PLANT -III

Pressure build up time

MAHAVIR DIE CASTERS PLANT -III

Benefit to organization:

• Increase plunger life.• Increase machine capability. • Minimize injection unit leakage.• Increase machine clamping capability.• Increase die life.

MAHAVIR DIE CASTERS PLANT -III

MAY JUNE JULY0

10

20

30

40

50

60

Monthly Plunger Consumption

70mm 80mm

MAHAVIR CASTERS PLANT -3

THANKS

MAHAVIR DIE CASTERS PLANT - III