project qa 2015 prakash

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To enhance the knowledge management of QA casting

and forging store by making check sheets for critical

dimensions and pictorial inspection procedure

for different families of

castings, forgings and machined components

Vocational Training Project

By

Prakash Bharati

Dept. of Mechanical Engineering

JADAVPUR UNIVERSITY, KOLKATA

Under the Guidance of

Mr. Manpreet Singh Marwah Senior Manager

Materials Engineering Group Quality Assurance

THCM, Jamshedpur

May 25th, 2015 to June 25th, 2015

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Certificate

This is to certify that project report entitled “To make

check sheets for critical dimensions and pictorial

inspection procedure for different families of castings,

forgings and machined components” submitted by

“Prakash Bharati” is a bonafide project work carried

out by him under my guidance. In my opinion the work

fulfills the requirement for which it is being submitted.

Place: THCM, JSR Project Guide Date: 25/06/2015 Mr. Manpreet Singh Marwah

Senior Manager Materials Engineering Group

Quality Assurance THCM, Jamshedpur

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ACKNOWLEDGEMENT

I would like to thank the Management of TATA HITACHI CONSTRUCTION

MACHINERY CO. PVT. LTD. (JAMSHEDPUR) for giving me this wonderful

opportunity to work with highly knowledgeable people on a project of

great importance.

I sincerely acknowledge the help and guidance received from Mr.

Manpreet Singh Marwah (Senior Manager) without whom it would have

been difficult to complete this project work. His constant encouragement

and words of motivation have been a source of inspiration for me. His

guidance from the very first day helped me develop an understanding of

the project.

I owe my deepest gratitude to Mr. Himanshu Pratap Singh (Asst.

Manager) for the valuable inputs provided by him at each and every step

of the project and this project would have been incomplete without his

help.

I acknowledge the help provided by Mr. A.N. Mohanta (Asst. Engineer).His

vast experience in this field helped me to get a better understanding of

this project and his constant help during this period helped me to

complete the project.

I also want to thank Mr. Monikut Sharma (Divisional Manager) &

Mr. Kumar Jagat (Asst. Divisional Manager) for providing us an

opportunity to present this work.

I convey my deep appreciation to all the technical and administrative

staffs at LMS STORE.

PRAKASH BHARATI

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CONTENTS

SL NO. TITLE PAGE NO.

ACKNOWLEDGEMENT 3

CONTENTS 4-6

1 ABOUT TATA HITACHI 7

1.1 INTRODUCTION 7-8

1.2 ENVIRONMENT 9-15

1.3 VISION AND MISSION 16

1.4 CORPORATE SOCIAL RESPONSIBILITY 17-19

1.5 INDUSTRY SOLUTIONS 20-21

2 QUALITY ASSURANCE 22

2.1 INTRODUCTION 23

2.2 FUNCTION 23

2.3 TESTING METHODS 24-28

3 PART-1 : FORMATION OF FAMILIES 29

3.1 INTRODUCTON 30

3.2 PROCEDURE 30

3.3 CONTENTS OF THE TABLE 31 - 33

3.3.1 COMMON TYPES OF PARTS FROM SEVEN MAJOR VENDORS 31

3.4 LIST OF IMPORTANT FAMILIES 34-35

3.4.1 GEAR PLANETARY 34

3.4.2 CARRIER 34

3.4.3 PIN 34

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3.4.4 TOOTH ADAPTER 35

3.4.5 BOSS 35

3.4.6 BUSH 35

3.4.7 SPROCKET 35

4 PART-2 PICTORIAL INSPECTION OF CRITICAL DIMENSIONS 36

4.1 INTRODUCTION 37

4.2 INSPECTION PROCEDURE 37

4.3 PICTORIAL INSPECTION FLOW CHARTS 38-72

4.3.1 BOOM CENTRE BOSS 38-39

4.3.2 ARM BOSS 40-41

4.3.3 BOOM FOOT BOSS 42-44

4.3.4 BUSH 45-47

4.3.5 CARRIER 48-53

4.3.6 CENTRE JOINT BODY 54-56

4.3.7 GEAR PLANETARY 57-58

4.3.8 PIN 59-60

4.3.9 SPROCKET 61-63

4.3.10 TOOTH ADAPTER 64-68

4.3.11 TOOTH POINT 69-72

5 PART-3 CHECKSHEETS FOR CRITICAL DIMENSIONS 73

5.1 INTRODUCTION 74

5.2 CHECK SHEETS 75-95

5.2.1 BOSS 74

5.2.2 BUSH 75

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5.2.3 CARRIER 76

5.2.4 CENTRE JOINT BODY 77

5.2.5 GEAR PLANETARY 78

5.2.6 PIN 79

5.2.7 SPROCKET 80

5.2.8 TOOTH ADAPTER 81

5.2.9 TOOTH POINT 82

5.2.10 BEARING 83

5.2.11 COVER 84

5.2.12 DRUM 85

5.2.13 GEAR SUN 86

5.2.14 IDLER 87

5.2.15 NUT 88

5.2.16 SHAFT 89

5.2.17 SHROUD 90

5.2.18 SLEEVE 91

5.2.19 SPINDLE 92-93

5.2.20 YOKE 94

6 SUMMARY 96

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ABOUT TATA HITACHI

1.1) INTRODUCTION Tata Hitachi Construction Machinery Co. Pvt. Ltd, the Leader in Construction Equipment in India, enhances the operational performance of its customers, leading to improving their profitability and competitiveness by offering constructive solutions. Tata Hitachi is a subsidiary company of Hitachi Construction Machinery Co. Ltd., which holds 60% share, and Tata Motors Ltd holding the balance 40%. The company commenced manufacturing of construction equipment in 1961, as a division of TELCO. In 1984, it entered into a technical collaboration with HCM, Japan for manufacturing state of the art hydraulic excavators. Tata Hitachi is focused on capitalizing the opportunity in the domestic arena for which the key market segments are Excavators, Wheeled Products, Cranes and Others. Tata Hitachi's consistent growth and success have been built on the foundation of our ability to understand customers' needs and provide Equipment and Support solutions that increase profitability and competitiveness for them. What we call Reliable Solutions. Our capabilities to deliver Reliable Solutions starts with our comprehensive range of Equipment that ensures that the customer has exactly the right kind of equipment for all Mining, Infrastructure, Construction and Agricultural needs. The construction industry involves heavy use of excavators, wheel loaders, and backhoe loaders. Tata Hitachi's range of excavators starting at 2 tonnes with a maximum size of 120 tonnes is made in the country. But sizes even bigger than this including the giant 250 tonne excavator have been brought in from Tata Hitachi's Principals, Hitachi Construction Machinery Limited, Japan. Tata Hitachi is one of the largest manufacturers of construction equipment in the country and has three manufacturing plants - at Jamshedpur in Jharkhand, at Dharwad in Karnataka and at Kharagpur in West Bengal. It also has a full – fledged Design and Development set-up for developing indigenous and collaborated equipment’s . Hitachi is actively participating in creating the new R&D facilities at Kharagpur with the aim to make the new centre a global R&D hub. Our endeavour to provide Reliable solutions is enabled by our widespread network, which ensures that wherever they are, our customers are never too far away from us. Tata Hitachi Dealers provide support to the customers through parts and expert service. Tata Hitachi takes pride in its marketing and

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service network of 230+ touch points that enables it to have one of the largest distribution networks in the country. Our focus is also on Value added Service offerings such as Full Maintenance Contracts, which complete our package to our customers and enable him free up precious resources for his core activities. Specialized reconditioning and refurbishing services are offered to ensure that the utility of the equipment is extended and life cycle costs brought down.

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1.2) ENVIRONMENT THCM is in the business of designing, manufacturing, marketing, selling

and servicing a wide range of construction equipment as shown in table below

Hydraulic Excavators

Mini Excavators

Backhoe

Model Engine Power Operating Weight Bucket Capacity

TMX 20-2 28 HP 2,200 kg 0.04 - 0.12 m3

ZAXIS 50 36 PS 4,810 kg 0.16 - 0.18 m3

EX 70 55 PS 7,000 kg 0.10 - 0.30 m3

ZAXIS 75 55 PS 7,400 kg 0.30 m3

EX 110 76 PS 11,000 kg 0.25 - 0.65 m3

ZAXIS 120H 90 PS 12,800 kg 0.19 - 0.70 m3

Shovel

EX 110 76 PS 11,600 kg 0.6 m3

Midi Excavators

Backhoe

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EX 200 LCi 125 PS 20,000 kg 0.8 - 0.91 m3

ZAXIS 210 LCH 150 PS 21,000 kg 0.9 - 1.1 m3

ZAXIS 220 LC 170 PS 21,700 kg 0.45 - 1.0 m3

EX 350 LCH-V 230 PS 34,000 kg 1.3 - 1.90 m3

ZAXIS 370 LCH 250 PS 35,400 kg 1.3 - 2.1 m3

Shovel

EX 200 LCi 125 PS 20,150 kg 1.32 m3

Large Excavators

Backhoe


ZAXIS 450 H 320 PS 45,100 kg 1.9 - 3.0m3

ZAXIS 650 H 400 PS 57,600 kg 3.3 - 3.8 m3

EX 1200 V 760 HP 1,11,000 kg 5.0 - 6.5 m3

EX 1900-6 1086 HP 1,91,000 kg 4.4 - 12.0 m3

EX 2600-6 1500 HP 2,54,000 kg 17.0 m3

EX 3600-6 1900 PS 3,59,000 kg 22 m3

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EX 5600-6 2 x 1500 HP 5,37,000 kg 34 m3

Shovel

ZAXIS 450 H 320 PS 46,100 kg 2.6 m3

ZAXIS 650 H 400 PS 60,500 kg 3.0 - 4.0 m3

EX 1200 V 760 HP 1,11,000 kg 5.9 - 6.5 m3

EX 1900-6 1086 HP 1,92,000 kg 11 m3

EX 2600-6 1500 HP 2,52,000 kg 15 m3

EX 3600-6 1900 PS 3,62,000 kg 21 m3

EX 5600-6 2 x 1500 HP 5,33,000 kg 29 m3

EX 8000-6 2 x 1940 HP 8,11,000 kg 40 m3

Excavator Loaders


TH 76 76 PS 7,200 kg 0.09 - 0.25 m

3 (B/H)

1 m3 (Loader)

TH 86 86 PS 7,500 kg 0.09 m

3 - 0.30 m

3 (B/H)

1 m3 (Loader)

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Wheel Loaders


TWL 3034 101.5 PS 10,470-10,600 kg 1.5 - 2.5 m3

TL 360 Z 130 PS 12,185 kg 1.5 - 3.0 m3

ZW 220 223 PS 17,800 kg 2.7 - 4.5 m3

ZW 310 299 PS 22,400 kg 3.4 - 4.2 m3

Transit Mixers

Model Engine Power Max Drum

Speed

Nominal

Capacity

TM 06

Super 51.4 Kw/70 HP 14 rpm 6 m

3

TM 08 75.7 Kw/101.5

HP 14 rpm 8 m

3

Dump Truck

Model Engine Power Max GMW Max Payload

EH 600 400 HP 58,490 kg 35.3 Ton

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Compactors

Name Model Engine Power Operating Weight

Soil Compactor VM3 102 HP @ 2300rpm 11,010 kg

Tandem Roller VTA 90 102 HP @ 2300rpm 9,500 kg

Motor Graders

Model Engine Power Operating Weight

TG 14 140 HP 14,040 kg

Cranes

Crawler Cranes

Model Engine Power Max Lifting Capacity

TFC 75 120 PS 25,000 kg

TFC 280 210 HP 75,000 kg

KH 500 250 PS 1,00,000 kg

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Hydraulic Cranes - Hitachi Sumitomo

Model

Max.

Lifting

Capacity

Load

Radius

( Mtrs)

Max Boom Length

(Mtrs)

Fly Jib

Length

(Mtrs)

SCX 400 40 T 3.7 46 15

SCX 550 55 T 3.7 42 15

SCX 700 70 T 3.5 54 18

SCX 800-

2 80 T 3.3 54.5 18

SCX 900-

2 90 T 4.0 6 28

SCX

1200-2 120 T 4.5 72 28

SCX

1500-2 150 T 4.1 75 28

SCX

2800-2 (N) 275 T 4.3 91.45 36.6

SCX

2800-2 (L) 80 T 9.4 61 61

6000 SLX-

N 500 T 6.0 96(H)/108(L)/72(Luff) 72(Luff)

6000 SLX-

T 500 T 7.3 96(H)/120(L)/84(Luff) 84(Luff)

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Tunnel Boring Machine - Hitachi Zosen

Type Diameter

Slurry Ø 2.53 to Ø 14.14 Mtrs

Earth Pressure Balanced Ø 2.336 to Ø 17.5 Mtrs

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1.3) Vision and Mission

VISION

Reliable Solutions

for Building a Greater

Tomorrow

MISSION

Be the preferred partner for providing reliable

solutions for mining and infrastructure sectors.

While dominating the domestic market, we will

become a global manufacturing and development

hub. Our hall mark shall be at our motivated people

customer-centric culture, superior technologies

and strong partnerships,all working safety in

unison with environment and safety.

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1.4) CORPORATE SOCIAL RESPONSIBILITY:

Tata Hitachi (THCM) has identified Corporate Social Responsibility (CSR) as on one of the Key Business Process. Tata Hitachi is committed to improving the quality of life of its identified communities located in and around the units of its operations. It shall strive to achieve this through periodical assessment of the needs of its communities and the continuous enrichment of the initiatives, designed to facilitate a process through which Tata Hitachi and its communities shall work as equal partners of social development. TATAHITACHI shall also strive to provide opportunity to its employees to volunteer their managerial, technical and specialized skills and services in order to enrich their lives, as well as to enable the company achieve its stated social responsibility of building strong communities, in creating a sustainable environment in and around its facilities. THCM CSR initiatives at Jamshedpur, Dharwad and Kharagpur is broadly

divided into:

Literacy Initiative:

THCM in its operational areas around its Plants at all locations has identified

schools which are catering mainly to underprivileged section of society.

Children from these schools are selected on merit cum need basis for providing

scholarships (50% of school fees), Books and uniforms.

THCM also provides infrastructure support to these schools to enhance the

quality of education to the children. THCM has helped these schools by building

a library, computer laboratory, boundary wall, vocational training workshop,

drinking water facilities for these schools.

THCM Graduate Engineer Trainees (GET’s) conduct an annual inter school

competition called JAGRITI for students of these schools for wherein there are

events like debate, quiz, extempore speech, singing, creative design, dancing

and drawing. This event provides a platform for these children to unleash their

talent, which helps them in developing their leadership quality, self confidence

and personality.

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Health Care Initiative:

THCM conducts Medical Check- up programmes in sponsored villages and

schools and provides treatment for various ailments. THCM also undertakes

repairing of tube wells and open wells for safe drinking water in sponsored

villages.

Rural Development Initiative:

THCM conducts various training programmes in the villages to enhance their

agricultural income through modern techniques. THCM assists the villagers in

reclamation of their barren land to bring it under cultivation. The Company also

helps the villagers in creating water harvesting structures to store rain water

for their use in house hold activities and other activities like pisciculture , duck

farming, vegetable farming etc. THCM has provided pipes and cable connection

for lift irrigation project in the Hurlung village, which has enabled the villagers

to bring 30 acres of land under multiple cropping. Good varieties of high yield

hybrid seeds were also given to farmers for vegetable cultivation.

Skill Development Initiative:

The Company has set up an Operator Training School at Kharagpur. It rests on

multiple pillars of skill building, social entrepreneurship and training. The

school imparts driving and servicing skills for excavators and backhoe loaders to

the unemployed youth to enhance their employability as operators for

construction equipment both in India and abroad. And as a policy 50 per cent

of the seats have been kept reserved for SC and ST candidates. The school has a

modern hostel, multiple class rooms supported by electronic visual aids and to

add to this the Company has put in place its state-of-the art machines amongst

others for practical sessions and for imparting world class training. The

program includes theory on equipment, practical and hands on training for

aggregates. A team of well trained and experienced personnel in the field of

training from the Company is leading the initiative.

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Operator cum mechanic training at Operator Training Centre

The initiative does not end here. The Company has taken it even further

wherein it maintains a data of trained personnel and shares information on its

trained operators to its dealers at all levels and new customers entering the

business for employment. It will ultimately usher in a supply chain

management system connecting supply of trained resource to its demand. This

will be noteworthy and is sure to make a sustainable contribution to the hugely

growing infrastructure sector in the country. Our engagement process at the

training centre goes a little beyond training. It aims at creating a corporate

sustainability programme, creation of human capital, leadership, and skill

building. Ultimately the emerging 3D vision out of this will focus on positive

economic value addition , social entrepreneurship, flanked by the twin pillars of

growth and sustainability. To further enhance the employability arena, the

Company provides four wheel driver training to village youths and tailoring to

ladies groups in the villages.

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1.5) INDUSTRY SOLUTIONS:

Mining

Tata Hitachi Construction Machinery (THCM) has been in the frontline in

providing complete solutions to the Mining Industry from the early beginnings

in cable shovels and Backhoes in the 60’s. With the advent of the Hydraulic

Excavators era, the Company introduced first the UH series and then the EX

series in India giving a new dimension to the Indian mining industry in

productivity and maintenance costs. The EX1200, a 100T class of excavator with

6.5 cum bucket has been a significant player in the Mining segment cutting

across various applications such as Coal, Iron ore and Limestone excavation.

The focus has been the profitability of customers through high fuel efficiency

and low operating costs . The Company also introduced the concept of the Full

Maintenance Contract which ensured the availability of equipments to the

customers and ensured better life and higher utilization levels of the

Equipment. The product mix in the Mining sector includes a range of

Excavators made in India complemented by Hitachi Construction Machinery’s

wide range going up to 800 T operating weight. These are matched with a

range of Dump Trucks.

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Infrastructure

Tata Hitachi Construction Machinery (THCM) offers a variety of solutions for

the infrastructure space. We straddle the entire range of equipment class by

tonnage; starting from the Mini Class of machines in the 2-7 T range, which

includes tracked excavators and wheeled equipment like the Excavator loaders.

These little masters go about doing their jobs deftly across applications while

remaining with in strict conforms of owning and operating costs.

The 10 - 20T class of tracked excavators, compactors and motor graders are the

“builders” that have literally built all key infrastructure in the last 20 years, then

be it India’s first Express highway between Mumbai & Pune in Roads, The iconic

Konkan Railway in Rail construction, The Tehri dam in Hydro power & Irrigation

and countless Commercial and Industrial Real estate development projects

across the country. It is hard being at a construction site without spotting one

these orange workhorses around you.

The 35T and above, class of equipment are called for when special applications

is the need of the hour, whether it is dredging of waterways, quarrying to

produce the Granite we all admire in our homes, offices and commercial spaces

or Material handling at Coal pit heads and ports, a THCM “hand” would always

be at hand and will prove to be more than handy.

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QUALITY

ASSURANCE

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2.1) INTRODUCTION Quality Assurance is a complete system to assure the quality of products or services. It is not only a process, but a complete system including also control. It is a way of management. Quality Assurance is a system for evaluating performance, service, of the quality of a product against a system, standard or specified requirement for customers. Quality Assurance is fundamentally focused on planning and documenting those processes to assure quality including things such as quality plans and inspection and test plans. QA is a part of quality management focused on providing confidence that quality requirements will be fulfilled. Quality assurance deals with the prevention of problems. Quality Assurance department deals with checking of the quality at every step so as to guarantee the production of a quality product. The major work of the quality department is to check for reports for any failure and find the causes of failure. The quality assurance has to check the quality of the incoming materials like the castings which come in from the vendors to check if they contain any defects like blowholes, shrinkage etc. It also has the responsibility of checking of the various sub parts in the intermediate stages such as after heat treatment, after machining, after or during fabrication in case any problem arises. It deals with prevention of quality problems through planned and systematic activities including documentation. It also deals with how to establish a good quality management system and the assessment of its adequacy& conformance audit of the operation system & the review of the system itself. QA is applied to physical products in pre-production to verify what will be made meets specifications and requirements, and during manufacturing production runs by validating lot samples meet specified quality controls. Two principles included in Quality Assurance are: "Fit for purpose", the product should be suitable for the intended purpose; and "Right first time", mistakes should be eliminated. QA includes management of the quality of raw materials, assemblies, products and components, services related to production, and management, production and inspection processes.

2.2) FUNCTION

The incoming materials are a majority of casting subparts coming from different vendors. Hence the main aim of the QA is to check whether the casting is made by the vendor is of the required quality or not and also whether they are made using the process specified by them in the contract. The function of the QA is also to check the cause of failure in case any failure is

http://en.wikipedia.org/wiki/Quality_(business)

http://en.wikipedia.org/wiki/Management

http://en.wikipedia.org/wiki/Inspection

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reported by the customer and check whether it is due to the casting or due to the wrong usage by the customer or any other reason for the matter

2.3) TESTING METHODS

. The major methods used by the QA department are-

Ultrasonic testing

Magnetic particle test

Dye penetration test

Radiographic test

Dimensional testing

ULTRASONIC TESTING

In ultrasonic testing (UT), very short ultrasonic pulse-waves with center frequencies ranging from 1-10 Hz are transmitted into materials to detect internal flaws or to characterize materials. Ultrasonic testing is often performed on steel. It is a form of non-destructive testing used in many industries including aerospace, automotive and other transportation sectors. In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed over the object being inspected. The transducer is typically separated from the test object by a couplant (such as oil) or by water, as in immersion testing. However, when ultrasonic testing is conducted with an Electromagnetic Acoustic Transducer (EMAT) the use of couplant is not required.

There are two methods of receiving the ultrasound waveform: reflection and attenuation. In reflection (or pulse-echo) mode, the transducer performs both the sending and the receiving of the pulsed waves as the "sound" is reflected back to the device. Reflected ultrasound comes from an interface, such as the back wall of the object or from an imperfection within the object. The

http://en.wikipedia.org/wiki/Automotive

http://en.wikipedia.org/wiki/Ultrasonic_sensors

http://en.wikipedia.org/wiki/Electromagnetic_acoustic_transducer

http://en.wikipedia.org/wiki/Electromagnetic_acoustic_transducer

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diagnostic machine displays these results in the form of a signal with an amplitude representing the intensity of the reflection and the distance, representing the arrival time of the reflection. In attenuation (or through-transmission) mode, a transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Imperfections or other conditions in the space between the transmitter and receiver reduce the amount of sound transmitted, thus revealing their presence. Using the couplant increases the efficiency of the process by reducing the losses in the ultrasonic wave energy due to separation between the surfaces.

MAGNETIC PARTICLE TEST

Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and slightly subsurface discontinuities in the various parts being made here. The process puts a magnetic field into the part. The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs when the electric current is passed through the test object and a magnetic field is formed in the material. Indirect magnetization occurs when no electric current is passed through the test object, but a magnetic field is applied from an outside source. The magnetic lines of force are perpendicular to the direction of the electric current which may be either alternating current (AC) or some form of direct current (DC) (rectified AC). The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to leak, since air cannot support as much magnetic field per unit volume as metals. Ferrous iron particles are then applied to the part. The particles are in a wet suspension. If an area of flux leakage is present, the particles will be attracted to this area. The particles will build up at the area of leakage and form what is known as an indication. The indication can then be evaluated to determine what it is, what may have caused it, and what action should be taken, if any. The magnaflux machine is used here for the magnetic particle inspection.

DYE PENETRATION TEST

Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or penetrant testing (PT), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-ferrous materials and ferrous materials; although for ferrous components magnetic-particle

http://en.wikipedia.org/wiki/Amplitude

http://en.wikipedia.org/wiki/Arrival_time

http://en.wikipedia.org/wiki/Non-destructive_testing

http://en.wikipedia.org/wiki/Alternating_current

http://en.wikipedia.org/wiki/Direct_current

http://en.wikipedia.org/wiki/Magnetic_flux

http://en.wikipedia.org/wiki/Porosity

http://en.wikipedia.org/wiki/Magnetic-particle_inspection

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inspection is often used instead for its subsurface detection capability. LPI is used to detect casting, forging and welding surface defects such as hairline cracks, surface porosity, leaks in new products, and fatigue cracks on in-service components. DPI is based upon capillary action, where surface tension fluid low penetrates into clean and dry surface-breaking discontinuities. Penetrant may be applied to the test component by dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess penetrant is removed and a developer is applied. The developer helps to draw penetrant out of the flaw so that an invisible indication becomes visible to the inspector. Inspection is performed under ultraviolet or white light, depending on the type of dye used - fluorescent or non-fluorescent (visible).

RADIOGRAPHIC TEST

Radiographic Testing (RT), or industrial radiography, is a nondestructive testing (NDT) method of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic radiation (high energy photons) to penetrate various materials.

Either an X-ray machine or a radioactive source, like Ir-192, Co-60, or in rarer cases Cs-137 are used in a X-ray computed tomography machine as a source of photons. Neutron radiographic testing (NR) is a variant of radiographic testing which uses neutrons instead of photons to penetrate materials. This can see very different things from X-rays, because neutrons can pass with ease through lead and steel but are stopped by plastics, water and oils.

Since the amount of radiation emerging from the opposite side of the material can be detected and measured, variations in this amount (or intensity) of radiation are used to determine thickness or composition of material. Penetrating radiations are those restricted to that part of the electromagnetic spectrum of wavelength less than about 10 nanometers . Defects such as delamination’s and planar cracks are difficult to detect using radiography, which is why ultrasonic is the preferred method for detecting this type of discontinuity.

DIMENSIONAL TESTING

Various measuring instruments are used in order to check and determine the dimensions of the various parts. A few of them are-

http://en.wikipedia.org/wiki/Magnetic-particle_inspection

http://en.wikipedia.org/wiki/Porosity

http://en.wikipedia.org/wiki/Fatigue_crack

http://en.wikipedia.org/wiki/Capillary_action

http://en.wikipedia.org/wiki/Fluorescent

http://en.wikipedia.org/wiki/Industrial_radiography

http://en.wikipedia.org/wiki/Nondestructive_testing

http://en.wikipedia.org/wiki/Wavelength

http://en.wikipedia.org/wiki/Electromagnetic_radiation

http://en.wikipedia.org/wiki/Photon

http://en.wikipedia.org/wiki/Radioactive_source

http://en.wikipedia.org/wiki/Ir-192

http://en.wikipedia.org/wiki/Co-60

http://en.wikipedia.org/wiki/Cs-137

http://en.wikipedia.org/wiki/X-ray_computed_tomography

http://en.wikipedia.org/wiki/Neutron_imaging

http://en.wikipedia.org/wiki/Neutron

http://en.wikipedia.org/wiki/Nanometre

http://en.wikipedia.org/wiki/Delamination

http://en.wikipedia.org/wiki/Plane_(geometry)

http://en.wikipedia.org/wiki/Ultrasonic_testing

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a) HEIGHT GAUGE-

A height gauge is a measuring device used either for determining the height of the parts. Mitutoyo digital height gauge is used here. It can measure maximum up to height of 600mm. it has an automatic zero setter for taking our own reference origin or zero line.

b) MICROMETER

A micrometer sometimes known as a micrometer screw gauge, is a device incorporating a calibrated screw widely used for precise measurement of components. Here two types of micrometres are used digital micrometre and a general micrometre. They have their own respective calibrating sticks for calibration. They measure a maximum of 300mm. In case of any zero error the digital micrometre can be set to zero in that case. But in the case of the other micrometre it is necessary to take into consideration the zero error.

c) VERNIER CALIPER

A vernier scale is a device that lets the user measure more precisely than could be done by reading a uniformly-divided straight or circular measurement scale. It is scale that indicates where the measurement lies in between two of the marks on the main scale. Two types of vernier calipers are used here- digital vernier caliper with a zero error adjuster and a dial indicating vernier caliper whose zero error has to be checked and taken into consideration.

d) BORE GAUGE

A bore gauge is tool used for checking the dimension of a part. It is not used for the measurement of the inner diameter of the various parts. Bore gauge is calibrated using a micrometer. The deviation or zero error is calculated by checking the deflection in the dial of the bore gauge. Bore gauge tells us by how much a certain dimension varies from a certain given dimension but it does not help us in measurement of the dimension of the part.

http://en.wikipedia.org/wiki/Screw

http://en.wikipedia.org/wiki/Accuracy_and_precision

28 | P a g e

e) BEVEL PROTRACTOR

A bevel protractor is a graduated circular protractor with one pivoted arm; used for measuring or marking off angles. Sometimes Vernier scales are attached to give more precise readings. It has wide application in architectural and mechanical drawing, although its use is decreasing with the availability of modern drawing software or CAD. Universal bevel protractors are also used by toolmakers; as they measure angles by mechanical contact they are classed as mechanical protractors. The bevel protractor is used to establish and test angles to very close tolerances. It reads to 5 minutes or 1/12°] and can measure any angle from 0° to 360°. To measure an angle between the beam and the blade of 90° or less, the reading may be obtained direct from the graduation number on the dial indicated by the mark on the swivel plate. To measure an angle of over 90°, subtract the number of degrees as indicated on the dial from 180°, as the dial is graduated from opposite zero marks to 90° each way. Since the spaces, both on the main scale and the Vernier scale, are numbered both to the right and to the left from zero, any angle can be measured. The readings can be taken either to the right or to the left, according to the direction in which the zero on the main scale is moved.

http://en.wikipedia.org/wiki/Vernier_scale

http://en.wikipedia.org/wiki/CAD

29 | P a g e

PART - 1 TO FORM FAMILIES OF

DIFFERENT PARTS BY

CONSOLIDATING A LIST

FOR ALL THE INCOMING

PARTS TO THE

CASTING/FORGING STORES

30 | P a g e

3.1) INTRODUCTION

The THCM plant in Jamshedpur does not have its own foundry, hence the various parts products manufactured by the company are given out to contractors or vendors for being made through casting. Currently there are 39 vendors for casting and Machining parts. The main aim of the project is to form a family of similar products by consolidating various products being made by the vendors into a separate list containing all the basic details of the part. The list contains details of the casting and machining part such as the part number, the description of the part, the vendor code and the quantity of incoming parts to the casting and forging stores.

3.2) PROCEDURE

1) The list of incoming parts was downloaded from SAP for the period 01/04/2014 to 31/03/2015.

2) Total incoming part for 1 year = 1,46,976 units

3) Total incoming parts was filtered and sorted for 7 major vendors since contribution from these vendors are 1,22,909 units which is 83.62% of total incoming components. The seven vendors are listed below:

1) JMT Auto Ltd.

2) Mayura Steels Pvt. Ltd.

3) Ramakrishna Forging Pvt. Ltd.

4) India Forging and Stamping (IFS)

5) India Forging and Engineering (IFE)

6) Multitech Component Pvt. Ltd.

7) Newco Auto

4) Different families were formed based on the similar category of components from the total incoming parts of one year. The different families formed are Gear Planetary, Carrier, Pin, Tooth adapter, Tooth Point, Boss, Bush, Housing, Yoke, Sprocket, Nut, Gear, Shaft, and Sleeve etc.

31 | P a g e

3.3) CONTENTS OF THE TABLE

The table contains the details of the parts such as the part number, its name, the vendor code and the incoming quantity annually.

The contents help give an overlook on the part and help in easy identification and help in tracking of the cast parts. The contents can be further explained as follows:

EXCERPT OF THE TABLE

TABLE 3.3.1: COMMON TYPES OF PARTS FROM SEVEN MAJOR VENDORS:

Part Number Part Name Qty Vendor

TB01034 ADJUSTER ASSY WITHOUT SPRING. 848 S5021M

TB00340 TR.ADJ(W/O SPR) 720 S5021M

TE04688@50 BUSHING(FIN.TURNED) 444 S5021M

3044121 PIN 10 S5021M

3084353 GEAR PLANETARY 2675 R24820

3037936 BOSS 1552 R24820

3082517@80 GEAR;PLANETARY (HOBBING DONE) 1170 R24820

2049585@50 SHAFT;PROP(FINISH TURN) 1126 R24820

1010204@45 SPROCKET 1069 M63200

TB01401 TOOTH ADAPTER 960 M63200

TE06513 TOOTH POINT 960 M63200

TB00204@55 IDLER (WITHOUT F/ HRD)) 804 M63200

SE00729/SF BUSH 2286 M04890

4126209 PIN 18.0X10M.0 1330 M04890

TD08458@50 FLANGE ( W/O BROACH ) 230 M04890

TC02154@60 SHAFT ( WITHOUT SPLINES ) 108 M04890

TE03584 WASHER 2495 J04610

3070162 AXLE 693 J04610

TB00841 BODY 645 J04610

TB00840 SPINDL 631 J04610

084085201@40 PLATE 15 I24820

1025957@40 GEAR;RING(ROUGH TURN) 117 I24820

2033231@20 RIM; SF 26 I24820

2044936@30 SHAFT;PROP(ROUGH TURN) 70 I24820

1022195/SF GEAR;RING (FORGING ) 447 I20780

2033066 BOSS 41 I20780

2040439@20 TRACK ADJUSTER CYL ROUGH MACHINED 10 I20780

3201N21@30 INTER HOIST SHAFT ( ROUGH TURN ) 4 I20780

32 | P a g e

1) PART NUMBER

All the different parts of a machine have their own specific number. They vary according to the part and according to the project as well. The casting parts have a “/C” in the end after the numerical number. For example-MC00289/C this specifies that it is a cast part no machining or further operation has been done on it whatsoever. The forging part have a “/SF” in the end after the part no which specifies that it is a forged part and has not undergone any other machining whatsoever. For example-3215T4/SF. When a certain operation is done the “/C” or “/SF” goes away and a “@” is added. Every operation results in an increase by ten. For example-18T5705@30 the “@30” means that three operations have been done on the part after the machine has come from the vendor after being cast. Hence it indirectly tells us the stage of the part. Upon completion the “@” is removed and we are left only with the main part number. Hence the part number tells us the status of the part and helps keep track of the part.

2) PART NAME

It gives the description of the part. Description tells us what the part is whether it is a pin, a pipe, or a gear etc. it gives the information of the part tells us its stage of machining if it is complete or a certain amount of machining has been done or it is just a fresh casting. It also gives a detailed description of the part for ex if it is a roller then if it is a vertical roller or a horizontal roller. It also sometimes gives the dimensions of the part for ex-BUSH RD 32X16 45C8 this gives the details of the dimensions of the job. It also tells us the stage of machining of the part for ex- BEVEL PINION (ROUGH TURN).

3) QUANTITY

It gives the total quantity of a particular part in the period 31/03/2014 to 1/04/2015.A particular component in a family which is most frequent in this period is chosen and pictorial inspection procedure for measuring critical dimensions (in castings, forgings, machined components, etc) is

33 | P a g e

made. Frequency of a particular component also tells us which component is more important on the basis of high demand.

4) VENDOR CODE

Every vendor has their own code based on the name of the vendor. This helps categorise the vendors. All the transactions are made using the vendor code only. From the vendor code it is easy to extract complete information of the vendor. When we enter the vendor code in SAP then we automatically get all the details related to the vendor their full name, their address etc. It makes categorising the vendors easily. For example- the vendor code of JMT IS J04610and so on.

34 | P a g e

3.4) LIST OF IMPORTANT FAMILIES:

TABLE 3.4.1: GEAR PLANETARY


3075002@110 GEAR;PLANETAR(W/O TEETH GRINDING) 1191 J04610

3075693@110 "GEAR;PLANETARY,SF" 187 J04610

3075723@110 "GEAR;PLANETARY,SF" 178 J04610

3075002@110 GEAR;PLANETAR(W/O TEETH GRINDING) 100 R24820

3075723@110 GEAR;PLANETARY,SF 20 R24820



3082517@80 GEAR;PLANETARY (HOBBING DONE) 1170 R24820


3053194@40 GEAR;PLANETARY(ROUGH TURN) 338 I24820

TD00740@20 GEAR (PLANETRY) ( ROUGH TURNED ) 40 I20780

TABLE 3.4.2: CARRIER


1009857 CARRIER 757 J04610

1010673 CARRIER 421 J04610

1011450 CARRIER 402 J04610

1022196 CARRIER 445 J04610

1022197 CARRIER 428 J04610

1022198 CARRIER 461 J04610

1025826 CARRIER 622 J04610

1025826/C CARRIER CASTING 8 J04610

TABLE 3.4.3: PIN


SE00062/SF PIN 658 M04890

SE00072/SF PIN 753 M04890

SE00074/SF PIN 392 M04890

SE00091/SF PIN 648 M04890

SE00092/SF PIN 739 M04890

SE00667/SF PIN 356 M04890

SE00979/SF PIN; SF 348 M04890

SE00980@100 PIN 363 M04890

SE00981@60 PIN 310 M04890

SE00982@60 PIN 307 M04890

35 | P a g e

TABLE 3.4.4: TOOTH ADAPTER


TD05992 ADAPTER 1 1/2" ASSY 5 M04890


TB00821 TOOTH ADAPTER(SIDE LOCKING TYPE) 64 M63200


TC02162 TOOTH ADAPTER 40 M63200

TD08414 ADAPTER;TOOTH (HORIZONTAL LOCK) 70 M63200

TD08459 ADAPTER;TOOTH (HORIZONTAL LOCK) 139 M63200

TABLE 3.4.5: BOSS


4293526 BOSS 68 J04610

4385458 BOSS 97 J04610

2031101 BOSS(BOOM CENTER) 19 R24820

2057571 BOSS 48 R24820

2057732 BOSS(BOOM CENTER) 64 R24820

2033066 BOSS 41 I20780

4258101 BOSS 25 I24820

TABLE 3.4.6: BUSH


WE00599@70 BUSH; SEMI FINISHED 493 M04890

WE01086@40 BUSH ;SF 100 M04890

3040795@65 BUSHING 4 S5021M

3060476@40 BUSHING ;SF 317 S5021M

3094967@40 BUSHING ;SF 100 S5021M

4098099@40 BUSHING SF 141 S5021M

4099416@40 BUSHING;SF 55 S5021M

TABLE 3.4.7: SPROCKET


1010204@45 SPROCKET 1069 M63200

1010956@50 SPROCKET(W/O INDUCTION HARDENING) 9 M63200

1018740@15 SPROCKET; SF MACHINED 869 M63200

1022168@40 SPROCKET /SF 781 M63200

TB01070@40 SPROCKET MACHINED 12 M63200

36 | P a g e

PART -2 PICTORIAL INSPECTION

PROCEDURES FOR

MEASURING CRITICAL

DIMENSIONS IN

CASTINGS,FORGING AND

MACHINED COMPONENTS

37 | P a g e

4.1) INTRODUCTION

Critical dimensions of a particular component means the fitment dimension and tolerated dimension mentioned in drawing is of utmost importance, whereas dimensions which are not changing from semi-finished to finished stage can act as critical dimension. Few dimensions which are critical in drawing require special skill or method to check these dimensions. Therefore checking method is tabulated in pictorial format which are critical and requires special skill.

4.2) INSPECTION PROCEDURE

1) Families are formed on the basis of data downloaded from SAP for the period Apr’14 to Mar’15.

2) The component with the highest frequency in each family was taken to check.

3) The drawings of the component were studied and Critical dimensions are noted.

4) The critical dimensions are measured and photographs were taken simultaneously for making pictorial inspection flowchart.

5) Above mentioned Flow Chart was made for different families.

38 | P a g e

4.3) PICTORIAL INSPECTION FLOW CHARTS

TABLE 4.3.1: BOOM CENTRE BOSS

Part Name Boom Centre Boss Date: 29/05/2015

Sl.No. Photograph Process

1 A hard paper is taken and a point is marked(O).

2 The radius to be measured is marked using a divider.

3 The radius profile is marked using the divider.

Checking Procedure of Boom Centre Boss

Checking Procedure of following dimension in boom centre boss:

1) To measure the radius.

30

RADIUS

Doc No: THCM'15-CF-01/a

39 | P a g e

4A radius profile is to be cut using a pair of scissors along

the marked radius.

5 The radius profile is put on the boss and is measured.

30.06

Part Name Boom Centre Boss Date: 29/05/2015


1The angle is measured using bevel protractor in the

shown way.

Checking Procedure of Boom Centre Boss

Checking Procedure of following dimension in boom centre boss:

1) To measure the angle.

22.5°

Doc No: THCM'15-CF-01/b

22.5°

40 | P a g e

TABLE 4.3.2: ARM BOSS

Part Name Arm Boss Date: 29/05/2015


1 Take a V-Block.

2 The boss is placed on the V-BLOCK.

3Both LOCATION 1 and LOCATION 2 is maintained at zero

using height gauge to ensure that the boss is at the same

level with respect to base/surface table.

4Then the angle is measured using bevel protractor as

shown in the figure.

Checking Procedure of Arm Boss

Checking Procedure of following dimension in arm boss:

1) To measure the angle.

0.00

16.4°

ANGLE


16.4°

LOCATION 1 LOCATION 2

41 | P a g e

Part Name Arm Boss Date: 29/05/2015


1The inner diameter is measured using vernier

calliper(inner jaws).

21)The base of the inner diameter is taken as 0.

2)Taking the inner radius length in the height gauge the

centre is marked.

3 Now the centre is taken as 0.

4The height gauge is brought down till the base/surface

table and distance is measured.

Checking Procedure of Arm Boss

Checking Procedure of following dimension in arm boss:

1) To measure the distance between the centre and base.

98.18

0.00

90.49

DISTANCE

0.00

49.09


90

42 | P a g e

TABLE 4.3.3: BOOM FOOT BOSS

Part Name Boom Foot Boss Date: 29/05/2015


1The distance is measured using vernier calliper(outer

jaws) by placing it on two extreme ends.

Checking Procedure of Boom Foot Boss

Checking Procedure of following dimension in boom foot boss:

1) To measure the distance between the opposite outer ends.

268.36


268



1Tap diameter is measured from inside of boss using

vernier calliper(inner jaws).



1) To measure the Tap diameter.

8.20


8

43 | P a g e



1

1)The boss should be kept in the position shown in the

photograph using Magnetic Block.

2)The perpendicularity is to be checked with respect to

base/surface table with the help of try square.



3 The base of the inner diameter is marked 0.

4Taking the inner radius in the height gauge,centre of the

boss is marked.The inner radius is taken as A.



1)To measure distance between the centre and base of the boss.

114.96

0.00

57.48

Doc No: THCM'15-CF-03/c

109.5

44 | P a g e

5Putting the vernier on the half line mark the thickness of

the boss is measured and is taken as B.

6 Therefore the distance is A+B.

B

DISTANCE

52.34



1The angle is measured using bevel protractor in the

shown way.



1)To measure the angle(6.8°).

6.8°

Doc No: THCM'15-CF-03/d

6.8°

45 | P a g e

TABLE 4.3.4: BUSH

Part Name Bush Date: 30/05/2015


1 A Bush is placed on a V-BLOCK.

2A dial gauge is taken and attached to the height gauge in

the following manner.

3Both the height gauge and dial gauge is to be marked 0

(as reference point) at the starting point of the

groove(just outside the groove).

Checking Procedure of following dimension in bush:

1)To measure the Groove Depth.

Checking Procedure of Bush

0.00

0.00


46 | P a g e

4Now the dial gauge is to be placed at the lowest point of

the groove and it is to be pressed or released until the

pressure becomes 0.(same as the reference)

5The reading on the height gauge is noted and it gives the

groove depth.

0.00

0.00

1.22

47 | P a g e

Part Name Bush Date: 30/05/2015


1 A Bush is placed on a V-BLOCK.

2The width of the groove is measured using digital vernier


Checking Procedure of Bush

Checking Procedure of following dimension in bush:

1)To measure the Groove Width.

6.77


48 | P a g e


Part Name Carrier Date: 28/05/2015


1 Place the carrier on the V-Block.

2Check the prependicularity of the face with

the base/surface table.

3Maintain the hole on the same level using

height gauge with respect to base/surface

table.

Checking Procedure of Carrier

Checking Procedure of following dimension in carrier:

1) Angle between the pad centre and planetary bore.

0.00

0.00

ANGLE = 60°


49 | P a g e

4Measure the hole diameter using vernier

calliper.

5 Taking zero at the base of the Hole.

6Marking to be done at half of the hole after

checking it with Vernier Calliper.

7

1)A proper reference point is marked on the

horizontal centre line of the bore.

2)Taking proper radius arcs are cut on both

sides of the bore and joined.

3)The line joining is extended to meet the

true centre of the carrier.

0.00

29.14

14.58

ARCS

50 | P a g e

8

1)A line parallel to the base is drawn on the

pad of the carrier(as shown in the

photograph).

2)A proper reference point is marked on the

line.

3)Taking proper radius arcs are cut on both

the sides and joined to get the pad centre.

9The line is extended and it intersects the

previous vertical centre line.

10The angle between the pad centre and

planetary bore is found to be 60°

60°



Checking Procedure of following dimension in carrier:

1) Pitch Circle Diameter.

P.C.D


51 | P a g e



calliper(inner jaws) and the distance is taken as

A.

2Distance between the inner diameter and the

base of the hole is measured and is taken as B.

3the hole diameter is measured.The radius of

the hole is taken as C.

4 Hence P.C.D is A+B+C.

91.57

34.40

29.14

A

B

P.C.D

52 | P a g e



1 Take an outside micrometer.

2

It is calliberated with its master test piece.

For example-the micrometer in the figure

matches with the 0 line and is calliberated to

50 mm.

Checking Procedure of following dimension in Carrier:

1)To measure the bore diameter.


50

BORE DIA

Doc No: THCM'15-CF-05/c

53 | P a g e

3A bore gauge is taken and adjusted according

to the bore diameter to be measured.

4

The bore gauge is placed in the outside

micrometer and using the dial gauge it is

calliberated according to the bore

diameter.The arrow should coincide with the

0 of the dial gauge.This value gives the lower

limit of the bore diameter.

5

The bore gauge is placed inside the planetary

bore and the deviation in the dial gauge from

0 gives the range.Here it is 0.03.Hence the

bore diameter is the lower limit+maximum

deviation in the needle(range).Here it is

52.03.

54 | P a g e

TABLE 4.3.6: CENTRE JOINT BODY

Part Name Centre Joint Body Date: 15/06/2015


1The centre joint body is sectioned into two halves and

one half is taken and chalked for the purpose of marking

and measuring the groove height.

2Both the outer sides of the centre joint body is

calliberated to zero to ensure that it is completely

vertical.

3The casting reference is calliberated to zero using the

height gauge.

Checking Procedure of following dimension in Centre Joint Body:

1)To measure the groove height .

Checking Procedure of Centre Joint Body

0.00

0.00


55 | P a g e

4The machining reference depth is taken and is marked

using the height gauge.

5The first groove height is measured(taking the casting

reference as the reference point).Similarly all the other

groove heights are measured according to the drawing.

101.02

75.01

Part Name Centre Joint Body Date: 15/06/2015


1The machining reference is calliberated to zero using a

height gauge.

Checking Procedure of Centre Joint Body

Checking Procedure of following dimension in Centre Joint Body:

1)To measure the left out space after making the groove.

16

55

0.00


56 | P a g e

2The height of the starting point of the groove from the

machining reference is taken in the height gauge and

marked.

31)The starting point of the groove is calliberated to zero.

2)The groove width(5) is taken from starting point of the

groove and marked using height gauge.

4

1)Then the end point of the groove is calliberated to

zero.

2)The left out space is then measured using height

gauge.Similarly all the other left out spaces are

measured.

16.00

0.004.96

0.00

5.30

57 | P a g e

TABLE 4.3.7: GEAR PLANEATARY

Part Name Gear Planetary Date: 28/05/2015




2

The root diameter = 106.60 is measured using vernier

calliper(outer jaws) by measuring distance between two

opposite ends.

REMARKS: This can only be measured if the number of

teeth is even or else it will be measured in CMM.

3

The tip diameter is measured using vernier calliper(outer

jaws) by measuring distance between two opposite

ends.

REMARKS: This can only be measured if the number of

teeth is even or else it will be measured in CMM.

Checking Procedure of following dimension in Gear Planetary:

1)To measure the Inner Diameter.

2)To measure the Root Diameter.

3)To measure the Tip Diameter.

Checking Procedure of Gear Planetary

41.41

134.30

106.63

INNER DIA

ROOT DIA

TIP DIA


58 | P a g e

Part Name Gear Planetary Date: 28/05/2015


1Take the base/surface table as reference and mark it 0

using the height gauge

2Measure the height at location 1 and take it as reference

for checking parallelity.

3

Measure the height at Location 2 and at Location 3

.There is a variation from 0.01 to 0.07.The difference

between the maximum and minimum values at two

different locations is called PARALLELITY(e.g:here it is

0.07).

Checking Procedure of Gear Planetary

Checking Procedure of following dimension in Gear Planetary:

1)To measure the parallelity.

0.00

63.77

63.78

63.84Location 2

Location 1

Location 3


59 | P a g e

TABLE 4.3.8: PIN

Part Name Pin Date: 12/06/2015


1 A BENCH CENTRE TABLE is to be used.

21)Clean the pin centre.

2)Place the pin between the chucks.

Checking Procedure of following dimension in Pin:

1)To measure the run out .

Checking Procedure of Pin

Doc No: THCM'15-CF-08

60 | P a g e

3Touching the dial gauge tip on the surface of the pin at a

fixed location and rotating the pin with hand and finding

out the minimum outer diameter.

4The minimum outer diameter is calliberated at 0 on the

dial gauge.

5

1)The pin is roatated keeping the dial gauge fixed and the

maximum deviation is noted.

2)The half of the maximum deviation from zero is the

run out of the pin.Here it is 0.02/2=0.01.

0.00

0.02

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Part Name Sprocket Date: 11/06/2015


1 A sprocket is placed on a wooden plank.

2 The outer teeth profile is marked using a pen.

3The marking is checked using a try square to assure that

the marking done and outer dia match.

Checking Procedure of following dimension in Sprocket:

1)To measure the pitch distance .

Checking Procedure of Sprocket

216.5

Doc No: THCM'15-CF-09

62 | P a g e

4 The inner dia profile is marked using a try square.

5The sprocket is removed from the plank and the inner

diameter is measured using a digital vernier


6

Taking half the length of the inner diameter on the

vernier calliper the centre of the sprocket is marked by

cutting the arcs.The arcs are cut by placing the vernier at

two different positions.

7Taking the length of the pitch circle radius from the

centre a profile is marked.

63 | P a g e

8The centre of the tooth tip is marked using a divider as

shown in the photograph.

9The centre of the alternate tip is also marked to measure

the pitch distance as shown on the top.

10The pitch distance is measured using a digital vernier


216.5

64 | P a g e


Part Name Tooth Adapter Date: 12/06/2015


1The tooth adapter is kept in a vertical position as shown

in the photograph with the help of magnetic V-Block.

2 The base/surface table is calliberated to zero.

3The height of the base of the hole is measured from both

the sides to ensure that the tooth adapter is completely

vertical.

Checking Procedure of following dimension in Tooth adapter:

1)To measure the width at the datum line .

Checking Procedure of Tooth Adapter

57.34


65 | P a g e

41)The hole diameter is marked.

2)The base of the hole is marked 0.

5Taking the hole radius on the height gauge the centre of

the hole is marked.

6

The depth of 39 is taken to mark datum line from

marked hole centre and is marked on all sides of the

tooth adapter using the height gauge.This point is named

as A.

7The width is measured at point A and as it is the required

fitment dimension..

0.00

Holeradius

39.00

A

66 | P a g e

8 Now the point A is marked Zero.

9The height of 45 is taken to mark the next datum line

from point A and is marked on all sides of the tooth

adapter using the height gauge.This point is named as B.

10The width is measured at point B as it is the required

fitment dimension.

0.00

45.00

73.33

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Part Name Tooth Adapter Date: 12/06/2015


1A tooth adapter is taken and tilted by the angle given in

the drawing.Here it is 10°.

2 The base of the hole is taken as 0.

Checking Procedure of Tooth Adapter

Checking Procedure of following dimension in Tooth adapter:

1)To measure the distance on both sides of the centre of the tooth adapter .

TILT BY 10°

0.00

53


68 | P a g e

3Taking the hole radius on the height gauge the centre of

the tooth adapter is marked.

4 The centre is marked 0.

51)The distance from the centre to the base is measured.

2)The distance from the centre to the top is measured.

Holeradius

0.00

53.5

69 | P a g e

TABLE 4.3.11: TOOTH POINT

Part Name Tooth Point Date: 15/06/2015


1

The tooth point is kept in a vertical position as shown in

the photograph with the help of magnetic V-Block.The

magnetic block is locked on one side to make proper

adjustments to assure that the block is vertical.

2Both the left and right sides are calliberated to zero to

ensure that the tooth point is completely vertical.

3The holes on the front side and back side are calliberated

to zero to ensure that the tooth point is at 90° with

respect to base/surface table.

Checking Procedure of following dimension in Tooth Point:

1)To measure the width at the datum line .

Checking Procedure of Tooth Point

0.00

0.00


70 | P a g e

4The V-Block is locked on both sides after calliberation to

avoid movement of tooth adapter.

5

1)The hole diameter is measured.

2)Thebase of the hole is calliberated to zero.

3)Taking the hole radius the centre is marked using a

height gauge.

6The inner portion of the tooth point is chalked for

marking.

7The centre of the hole is marked zero on the height

gauge.

8

The depth of 43 is taken to mark datum line from

marked hole centre and is marked on all sides of the

tooth adapter using the height gauge.This point is named

as A.

26.94

13.47

0.00

A

71 | P a g e

9The width is measured at point A with the help of a

divider and as it is the required fitment dimension.

10 The point A is calliberated to zero.

11The height of 50 is taken to mark the next datum line

from point A and is marked on all sides of the tooth

adapter using the height gauge.This point is named as B.

12The width is measured at point B with the help of a

divider and as it is the required fitment dimension.

58.33

0.00

81.61

B

72 | P a g e

Part Name Tooth Point Date: 15/06/2015


1The inner jaws of the vernier calliper is placed at the

intersection of the straight line and curve and the width

is measured.

Checking Procedure of Tooth Point

Checking Procedure of following dimension in Tooth Point:

1)To measure the width at the intersection of the straight line and curve of the tooth point .


86.65

73 | P a g e

PART -3 CRITICAL DIMENSIONS

CHECK SHEETS FOR

DIFFERENT FAMILIES OF

INCOMING

COMPONENTS AT

CASTING/FORGING

STORES

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5.1) INTRODUCTION

The drawings were studied of different families made in PART-1 and the critical

dimensions were marked as shown in the check sheets below. These Critical

dimensions of a particular component were chosen on the basis of the fitment

dimension and tolerated dimension mentioned in drawing which is of utmost

importance, whereas dimensions which are not changing from semi-finished to

finished stage can act as critical dimension.

The contents of the table are:

1) Parameter: These are the different nomenclature of critical dimensions

which are to be measured (Eg: Height, Thickness, Angle, Width etc.)

2) Specification: These are the actual dimensions mentioned in the

drawings which are to be checked using proper checking instruments.

3) Tolerance: This gives the dimensional range of the mentioned

specification depends on whether the component is casting, forging or

machined. The tolerance of the machined components is lesser compared to

casting. For eg: if the specification of a particular component is 75 and

tolerance is ± 0.30 then the range of the specification is from 74.70 to 75.30.

4) Checking Instrument: It tells us about the instrument from which the

dimension of a particular specification is to be measured. The instrument is

chosen based on the tolerance of a particular specification.

Least count of instrument used should be less than or equal to 1/10th of the

given tolerance range. For eg:

a) If tolerance is ± 0.50mm, then the range of tolerance is 1mm, therefore

it can be checked with the instrument having maximum least count of

0.1mm.

b) If tolerance is ± 0.020mm, then the range of tolerance is 0.040mm,

therefore it can be checked with the instrument having maximum least

count of 0.004mm.

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5.2) CHECK SHEETS

TABLE 5.2.1: BOSS

PART DESCRIPTION Doc No. Rev Date Rev No.

Boom Centre Boss THCM'15-CF/CD-01 22-06-2015 0

Sl.No Parameter Specification Tolerance Checking Instrument Observation

1 Height 75.00+2.10

-1.10Digital Height Gauge

2 Dia 74.00+2.10

-1.10Digital Vernier Calliper

3 Dia 152.00-0.10


4 Height 65.00+2.10


5 Height 97.00+2.10


6 Thickness 14.00+1.50


7 Angle 22.5° ± 0.5° Bevel Protractor

8 Dia 70.00+2.10


9 Outer Dia 290.00+3.00


Accepted

Rejected

Inspection Report Of Boom Centre Boss

Checked ByRemarks

Approved By

Part No.

3037936

1

2

3

4

567

8

9

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TABLE 5.2.2: BUSH


Bush THCM'15-CF/CD-02 22-06-2015 0


1 Height 123.000.00


2 Inner Dia 109.50+0.10

+0.00Digital Vernier Calliper

3 Outer Dia 131.00+0.10


4 Groove Width 7.00 ± 1.00 Digital Vernier Calliper

5 Depth 1.30 ± 0.30 Digital Height Gauge

Accepted

Rejected

Inspection Report Of Bush

Checked ByRemarks

Approved By

Part No.

3060476

1

2 3

4

5

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Carrier THCM'15-CF/CD-03 22-06-2015 0


1 Dia 159.500.00


2 Dia 154.000.00


3 Dia 140.00 ± 2.50 Digital Vernier Calliper


5 Angle 30° 0.5° Bevel Protractor

6 Height 40.00 ± 1.80 Digital Height Gauge



0.00Digital Vernier Calliper

9 Height 95.00+0.25


10 Height 65.40+0.50

+0.60Digital Height Gauge


12 Dia 40.00+0.040

+0.000Dial Bore Gauge


14 Outer Dia 272.00 ± 3.10 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Carrier

Checked ByRemarks

Approved By

Part No.

1009857

1 2

3

4

5

6

7 89

10

11

12

13

14

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TABLE 5.2.4: CENTRE JOINT BODY


Centre Joint Body THCM'15-CF/CD-04 22-06-2015 0


1 Height 223 ± 2.80 Digital Height Gauge









10 Length 25 ± 1.00 Digital Height Gauge




14 Dia 90+0.090

+0.090CMM

15 Dia 90+0.180

-0.140CMM

16 Dia 122+2.00


17 Width 106 ± 0.20 Digital Vernier Calliper

18 Width 130 ± 2.50 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Centre Joint Body

Checked ByRemarks

Approved By

Part No.

SB00040

18

17

16

15

14

1

23 4

5

6 7 89

1011

12

13

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TABLE 5.2.5: GEAR PLANETARY


Gear Planetary THCM'15-CF/CD-05 22-06-2015 0


1 Inner Dia 57.00+0.031


2 Thickness 31.500.00


4 Outer Dia 117.000.00


Accepted

Rejected

Inspection Report Of Gear Planetary

Checked ByRemarks

Approved By

Part No.

3075693@110

1

2

3

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TABLE 5.2.6: PIN


Pin THCM'15-CF/CD-06 22-06-2015 0



2 Height 62.00 ± 0.30Digital Height Gauge &

Digital Vernier Calliper

3 Height 289.00 ± 0.80Digital Height Gauge &

Digital Vernier Calliper


5 Dia 71.00-0.10

-0.17Outside Micrometer

6 Thickness 40.00 ± 0.30 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Pin

Checked ByRemarks

Approved By

Part No.

WD00005

1 2

3

4

5

6

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Sprocket THCM'15-CF/CD-07 22-06-2015 0




2 Radius R10 ± 1.40 Radius Gauge







9 Dia 419.00+0.30



11 Hole Dia 16.00-22.00+0.30


12 P.C.D 464.00 ± 3.50 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Sprocket

Checked ByRemarks

Approved By

Part No.

1018740

1

2

3

4

5 6

7 8

10

9

11

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Tooth Adapter THCM'15-CF/CD-08 22-06-2015 0


1 Width 72.70 ± 2.20 Digital Vernier Calliper



4 Hole Dia 20.00 ± 1.60 Digital Vernier Calliper





9 Length 41.00+2.00




Accepted

Rejected

Inspection Report Of Tooth Adapter

Checked ByRemarks

Approved By

Part No.

TB01401

1

2

3 4

8

7

5 6

9

10 11

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TABLE 5.2.9: TOOTH POINT


Tooth Point THCM'15-CF/CD-09 22-06-2015 0




3 Length 50.00 ± 0.25 Digital Vernier Calliper

4 Length 50.00 ± 2.00 Digital Vernier Calliper




7 Height 286.00 ± 3.10 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Tooth Point

Checked ByRemarks

Approved By

Part No.

TD09575

1

2

3

4

5

6

7

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TABLE 5.2.10: BEARING


Bearing THCM'15-CF/CD-10 22-06-2015 0


1 Dia 75.00+0.034

-0.030Inside Micrometer




5 Height 42.00+0.50



7 Dia 127.00+0.10


8 Dia 142.00+2.00


9 Outer Dia 160.00+2.00


10 Drill Dia 10.90 ± 1.50 Digital Vernier Calliper

11 Drill Dia 16.00 ± 1.50 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Bearing

Checked ByRemarks

Approved By

Part No.

1026776

1

2

3

4

6 5

9

8

7

10 11

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TABLE 5.2.11: COVER


Cover THCM'15-CF/CD-11 22-06-2015 0



2 Dia 332.00+0.20




5 Thickness 5.00 ± 0.20 Digital Height Gauge

6 Length 27.00 ± 0.30 Digital Height Gauge




Accepted

Rejected

Inspection Report Of Cover

Checked ByRemarks

Approved By

Part No.

2034833

1

2 3

4

5 6

7

8

9

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TABLE 5.2.12: DRUM


Drum THCM'15-CF/CD-12 22-06-2015 0


1 Height 143.00+0.50

0.00Digital Height Gauge

2 Dia 349.00+0.80


3 Dia 290.01-0.003

-0.054CMM

4 Height 59.75 ±0.10 Digital Height Gauge




8 Dia 412.00+0.073

+0.010CMM

9 Dia 481.000.000

-0.012CMM

10 Dia 568.00 ±3.50 Digital Vernier Calliper

11 Hole Dia 16.00 ±1.50 Digital Vernier Calliper

12 P.C.D 447.00 ±3.50 Digital Vernier Calliper

13 Hole Dia 20.00 ±1.60 Digital Vernier Calliper




Accepted

Rejected

Inspection Report Of Drum

Checked ByRemarks

Approved By

Part No.

1022179

1

2

3 4 5 6

7

8

9

10

11

13

14

15 16

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TABLE 5.2.13: GEAR SUN


Gear Sun THCM'15-CF/CD-13 22-06-2015 0


1 Dia 68.00+0.045

+0.020Dial Bore gauge

2 Parallelity 0.05 N.A. Digital Height Gauge

3 Dia 106.000.00


4 Outer Dia 112.000.00


5 Thickness 92.30-0.10


Accepted

Rejected

Inspection Report Of Gear Sun

Checked ByRemarks

Approved By

Part No.

3082156@60

1

2

3 4

5

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TABLE 5.2.14: IDLER


Idler THCM'15-CF/CD-14 22-06-2015 0


1 Height 63.00+0.00


2 Dia 36.00+0.025

+0.00Dial Bore Guage

3 Outer Dia 302.00+2.00


4 Thickness 31.00-0.50




7 Step 13.00 ± 0.10 Digital Height Gauge



Accepted

Rejected

Inspection Report Of Idler

Checked ByRemarks

Approved By

Part No.

SD00247

1

6

2

3

5

4 7

8

9

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TABLE 5.2.15: NUT


Nut THCM'15-CF/CD-15 22-06-2015 0










8 P.C.D. 151.00 ± 0.50 Digital Vernier Calliper

Accepted

Rejected

Inspection Report Of Nut

Checked ByRemarks

Approved By

Part No.

3099830

1

2

4

3

6

5

7

8

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TABLE 5.2.16: SHAFT


Shaft THCM'15-CF/CD-16 22-06-2015 0



2 Dia 32.70 0.00


3 Dia 39.50+1.30


4 Outer Dia 109.600.00





Accepted

Rejected

Inspection Report Of Shaft

Checked ByRemarks

Approved By

Part No.

2049585@50

1

2 3

4

5

6

7

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TABLE 5.2.17: SHROUD


Shroud THCM'15-CF/CD-17 22-06-2015 0


1 Length 70.00 ± 1.10 Vernier Calliper


3 Thickness 48.00 ± 1.40 Vernier Calliper

4 Thickness 15.00 ±1.10 Vernier Calliper

5 Thickness 20.00 ±1.20 Vernier Calliper

6 Length 125.00 ± 1.80 Vernier Calliper

Accepted

Rejected

Inspection Report Of Shroud

Checked ByRemarks

Approved By

Part No.

4257065

1

2

3

4

5

6

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TABLE 5.2.18: SLEEVE


Sleeve THCM'15-CF/CD-18 22-06-2015 0



2 Outer Diameter 252.70/252.60 ± 0.05 Digital Vernier Calliper

3 Thickness 35.000.00





Accepted

Rejected

Inspection Report Of Sleeve

Checked ByRemarks

Approved By

Part No.

3078670@50

1

2

3 5

4 6

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TABLE 5.2.19: SPINDLE


Spindle THCM'15-CF/CD-19 22-06-2015 0


1 Height 299.50+0.20













Inspection Report Of Spindle

Part No.

SB00090@50

1

2 3 4

5 6 7 8 9

10

11

12

13

14

15

16

17

23

22

21

20

19

18

24

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18 Dia 67.000.00


19 Dia 70.000.00


20 Dia 90.50/90.60 ± 0.05 Outside Micrometer

21 Dia 89.50 ± 0.50 Outside Micrometer

22 Dia 100.60/100.50 ± 0.05 Outside Micrometer

23 Dia 108.00 ± 0.50 Outside Micrometer

24 Thickness 10.00+0.50


Accepted

Rejected

Checked ByRemarks

Approved By

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TABLE 5.2.20: YOKE


Yoke THCM'15-CF/CD-20 22-06-2015 0


1 Dia 7.60+0.10





5 Height 10.00+0.15


6 Dia 40.00 ±0.30 Digital Vernier Calliper



Accepted

Rejected

Inspection Report Of Yoke

Checked ByRemarks

Approved By

Part No.

1017138

1

2

3

4

5

6

7

8

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SUMMARY:

To enhance the knowledge management of QA casting and forging store by documenting the inspection and drawing reading skills of the department members. The following work has been done to accomplish the same:

1) Families of similar components were formed after categorising the parts from the data downloaded for 7 vendors which accounts for 83.62 % of incoming components at casting & forging store for last financial year(2014-15).

2) The component with the highest frequency in each family was taken to inspect and pictorial procedure was tabulated for dimensions which are critical and requires special skills for inspection.

3) Check sheets were prepared for one part of a particular family to narrow down the critical dimensions for daily incoming inspection.

4) The pictorial inspection procedure and Check sheets can be followed for all the similar members of the family.

project qa 2015 prakash

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