Manufacturing Technology Today

G. Evangelin Paul ¹, P. Hema ¹, K. Venkata Muni ¹, K. Aruna ¹

Affiliations
1 S. V. University College of Engineering, Tirupathi, IN

Abstract

The core and the heart of the battery industry is Grid. This paper discusses about the quality and productivity improvement by reducing the rejections in Grid casting section in one of the Battery manufacturing Multinational companies. The quality improvement would be attained by sigma methodology’s DMAIC approach. It depicts reducing rejections in Grids from grid casting machine. Data collection and Pareto analysis indicated the high rejections are due to flashes and wire miss. The ischolar_main causes are found out by six sigma using Variable search tool and validated by Better Vs Current Tool. By the results of DMAIC, Modifications are carried out in grid casting methodology and the process parameters optimized. This resulted in reducing the rejections from 9.5 % to 2.1 % and average improvement of grid caster’s productivity. To confirm whether Six Sigma implementation would be simplified, this paper highlights usage of Shainin DOE instead of Taguchi DOE.

Keywords

Six Sigma, DMAIC, Pareto Analysis, Shainin DOE, Variable Search, Better Vs Current Tool.

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K. Devisree ¹, K. Aruna ¹, K. Venkatamuni ², P. Hema ¹

Affiliations
1 Dept. of Mechanical Engineering, SVU College of Engineering, Tirupathi, IN
2 Batteries Organization, IN

Abstract

SMED (Single Minute Exchange of Die) is one of the many Lean production methods for reducing time in a manufacturing process. The present paper deals with reduction in tool change time in one of the prime automotive batteries industry using SMED technique which increases productivity of the industry. In this project first the problem is identified in SBD (Small Battery Division) Plant based on analysis of one month data of plant capacity. After analysis, the bottleneck is identified for production of the plant using Pareto Analysis which indicates that the maximum tool change time due to Calibration and Assembly. Next SMED Methodology implemented on major areas to reduce the tool change time. The causes for recursive activities searched and ideas implemented to eliminate them provided. After implementing SMED technique the total tool change time for Calibration from 2192 to 1194 seconds and Assembly from 42 to 24 minutes reduced.

Keywords

SMED (Single Minute Exchange of Die), Lean Production, SBD (Small Battery Division), Pareto Analysis, Calibration and Assembly.

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K. Aruna ¹, R. Bhargav ¹, P. Hema ¹

Affiliations
1 Department of Mechanical Engineering, S.V.U. College of Engineering, Tirupati, IN

Abstract

Electrical Discharge Machining has been playing an important role in manufacturing sector especially industries like aerospace, ordinance, automobile, general engineering, etc. Electrical Discharge Machining (EDM) is one of the important non-traditional machining processes which is used for machining of conductive and semi conductive materials and also difficult to machine materials like super alloys and composites materials. However, selection of process parameters for obtaining higher cutting efficiency or accuracy in EDM is still not fully solved, even with the most updated EDM machine. An attempt is made in the present work to develop a prototype of EDM consisting of different units namely, dielectric filtering and recirculation unit, pulse generation and control unit and tool-feed control unit. They describe the utilization of various units and their components of proto-type EDM. Orthogonal Array, Taguchi Experimental design is developed for experimentation. The process parameters such as voltage, duty cycle and sensor value are by considered during machining. The experiments are carried-out to produce holes on copper plate using EDM Machine. The experimental results are analyzed and the optimal combinations of influential parameters are determined using Grey Taguchi Analysis. The optimum size of hole is obtained as 2.030 mm, at 40V and 0% Duty Cycle. The analysis is carried-out using Mini TAB and GRA.

Keywords

Die-Sinking EDM, Dielectric Filtering, Voltage, Duty Cycle, Grey Taguchi Method.

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T. Sai Kiran ¹, K. Aruna ¹

Affiliations
1 Dept. of Mechanical Engineering, S.V.U. College of Engineering, Tirupati, IN

Abstract

Abrasive Flow Finishing is one of the important non-convectional finishing process which is used to polish, deburr and finish internal surfaces. In this process, burrs or cutting marks are removed by allowing semi-solid, abrasive dispersed putty, with pressure into the workpiece material. In the present work, a prototype of Abrasive Flow Finishing Machine (AFFM) with pneumatic system is developed and used to finish the internal surfaces of the drilled hole on AISI 304 SS material. In this there are two operations are carried out, i.e. drilling and finishing operations by Abrasive Flow Finishing (AFF). First the hole is drilled with 10 mm size on the workpiece by varying speed and feed as input parameters followed by AFF operation with a pressure of 5 bar by using silicon carbide as abrasive with an abrasive mesh size (80 & 220) and number of cycles (5 & 10) considered as input parameters. The output responses for drilling and AFF operations are considered as initial surface roughness and final surface roughness. From the experiments, it is observed that abrasive mesh size and the number of cycles are playing a significant role in the AFF operation and to improve surface finish from 30 to 40% with minimum pressure of 5 bar by using pneumatic system.

Keywords

Abrasive Flow Finishing, Pneumatic Circuit, Silicon Carbide Abrasive Slurry, AISI 304 SS, Surface Finish.

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