Case Study
Case Study
Case Study
1. Company profile and information 2. Manufacturing products and procedure of the production. 3. Machines used in the company & their features and limitations. 4. Problem identification. 5. Causes of the tool wear. 6. Analysis of the different tools and features.
Company Name:
Chief Executive Officer :
Kinetic Gears
COMPANY PROFILE:
Business Type:
Supplier, manufacturer Year Of Establishment: 1980 Ownership Type: Sole Proprietorship Annual Turnover: Rs.50 Lakhs 1 Crore. Total Number Of Employees: 11-25 People.
MANUFACTURING PRODUCTS
Heavy Duty Industrial Gears
Mechanical Gears Precision Gears Cutting Tools
Gear Boxes
Automobile Gears Reduction Gears.
Mechanical gear
gear box
precision gear
Gear fan
Reduction gear
GENERAL PROCEDURE
DESIGN DRAWING OF PRODUCT
RAW MATERIAL
JOB DIMENSIONS
OPERATIONS
FINAL PRODUCT
OPERATIONS
MATERIAL
SIZES
TURNING
SHAVING
HOBBING
SLOTTING
MILLING
DRILLING
HARDENING
FINAL PRODUCT
POLISHING
GRINDING
Machines Used:
Milling
Lathe(cylindrical & turret lathe) Polishing (surface polishing machine)
Hobbing machine
Grinding machine Special Purpose machines(CNCs, VMCs)
CNC MACHINES
In modern CNC systems, end-to-end component
design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production.
that moves the component from machine to machine. The complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design. Normal working temperature is 33C. Cutting tool used in cncs is generally of cemented carbides. HSS and high carbon steel are used at high speed.
such a way that is harmful to the machine, tools, or parts being machined. This results in bending or breakage of cutting tools, accessory clamps, vices, and fixtures, or causing damage to the machine itself by bending guide rails, breaking drive screws, or causing structural components to crack or deform under strain.
hardness or shape), there will be problems the next time the job is run. It requires a great deal of duplicated effort since 3 CNCs are used. Reduced gripping force due to inadequate lubrication can cause malfunction. Moisture can occur in CNC controlling machine.
HOBBING MACHINES
Hobbing is machining process for making gears
spinles and sprockets on a hobbing machine, which is a special type of milling machine. Also called as hobbers fully automated machines can come in different sizes. Uses: cycloid gears, helical gears, worm gear spur gear, involute gear etc.
FEATURES
It is relatively quick and inexpensive.
They are fully automated. Lubrication is required.
POSSIBLE LIMITATIONS
Size changes during hob shifting. Size changes from part to part Rigidity of gear system and accuracy is reduced due to
long parts in gear trains. Stability of machine tool is adversely affected due to large openings and spaces required for gear boxes. Breaking of gears is possible due to high speed of operation. Thread deformation due to interruption in operation may occur.
TURRET LATHES
The turret lathe is a form of metalworking lathe that
is used for repetitive production of duplicate parts, which by the nature of their cutting process are usually interchangeable.
The general minor problems are like gear wear,
improper electric supply due to which job gets damaged and affect the production rate.
LIMITATIONS
Rate of tool feeding is slow in turret lathe providing
more fatigue to operators hand. Turret tooling is heavy, cumbersome, and slow to change out. Turning between centers is difficult due to absence of tailstock, compound rest, lead screw. Electric failure may result in reduced output quality.
tool used to provide precision ground surfaces, either to a critical size or for the surface finish. The typical precision of a surface grinder depends on the type and usage, however +/- 0.002 mm (+/- 0.0001") should be achievable on most surface grinders.
surface create residual stresses and a thin martensitic layer may form on the part surface; this decreases the fatigue strength. In ferromagnetic materials, if the temperature of the surface is raised beyond the Curie temperature then it may lose some magnetic properties. Finally, the surface may be more susceptible to corrosion.
VMC
FEATURES:
1. Fully tooled up solutions to meet the customer needs & Tool life management. 2. Chip Conveyor 3. High speed spindle up to 12000 rpm with chillier Flood Coolant System. 4. Coolant through Spindle. 5. Centralized & Programmable Lubrication 6. Carbide tool is generally used.
PROBLEM IDENTIFIED:
1. The machines like different lathes ,hobbing machine,CNCs have the general minor problems like gear wear in the lathes etc. 2. Since the machining work is more in the industry ,we have selected the TOOL WEAR as major problem for the ICS(Industrial Case Study). 3. So, considering this problem we have given the solutions for that.
adhesion and formation of metallic bonds formed over rubbing surface under load.
The tool material should be strong & hard enough to withstand the high
pressures without having brittle fracture(RBF=resistant to brittle fracture)
The tool material should be able to retain its strength and hardness at high
operating temperature. The tool material must have sufficient wear resistant i.e. Resistant to adhesion or diffusion at high temperatures
1. Carbon tool steels 2. Medium alloy steels 3. High speed steels 4. Cast alloy tools
Carbon tool steels: 1. Up to 1870, tools are all of this type only.. 2. Characteristics of the carbon tool steels are, low hot hardness and poor hardenability. 3. Compositions of carbon tool steel would have, carbon=0.8-1.3% silicon=0.1-0.4% manganese=0.2-0.4% 4. Higher the carbon content higher the hardness and high the wear resistance. Medium alloy steels: Differ from the plain carbon steel due to addition of alloy element to improve hardenability used for drills ,taps and reamers. Typical Medium Alloy Tool Steels,% C 1.2 1.2 1.2 S 0.3 0.3 0.3 Mn 0.6 0.7 0.3 Cr 0.5 0.5 0.7 Mo 0.5 0.3 W 1.5 Fe balance balance balance
0.8 % CARBON
2% V
6% W 4% Cr 5% Mo (invented in 1993)
HSS tools
1.
2. 3. 4.
Where, WC=tungsten carbide. Co= cobalt TiC=titanium carbide TaC =tantalum carbide(a kind of carbide ceramic)
Ceramics:
Also Called As Oxide Tool Materials. E.g.: aluminium oxide alumina(Al2O3). Since oxides are relevant to heat and do not soften at elevated temperatures. Oxide cutting tools reflect the high hardness and good wear resistant too.
Firstly introduced in the USA in 1955 and after that its properties are improved a bit till 1964.
Images of some ceramic tools as shown:
General remarks :
Materials having high young's modulus are more refractory (more hot hardness
character).
In an example , the hardness & strength oh the HSS fall rapidly above 500*c But cast cobalt alloys are softer than HSS at room temperature are harder at temp. Above 500*c Wide range of carbide characteristic is due to the variation in cobalt content which may vary between 3%-12%.
When cobalt content increased, the carbide becomes more ductile and shock resistant but less refractory. Still some materials recover there hardness value on cooling,
The ceramics,carbides,cast cobalt alloys recover there hardness completely but HC steel
soften irreversibly (above 500*c for HSS).
This is the one reason why HSS tools are limited to operations having working
temperature below 500*c.
Development in HSS involves ,atomization of pre alloyed HSS followed by consolidation into shanks by powder metallurgy technique, which gives uniform distribution of the
To increase the wear resistance of HSS, a hard layer contain upto 15%-20% V or Ti may be deposited on tough substrata.
Extremely hard but very thin surface layers have also been developed by VAPOUR
DEPOSTION OF CARBIDES.
FORD motor company uses improved TiC(titanium carbide) tools for cutting purposes because of there LOW density HIGH oxidation resistance ,which is having FOUR TIMES TOOL LIFE THAN other grades of carbides.
Mixture of Al2O3+TiC gives CERMETS, used in high speed machining of hard cast irons& hard steels too.
2.
3.
Coatings are form TiC,TiN,&Al2O3.while TiC & Al2O3 appear to have most
stable layer between the chip and tool. TiN=lowest tool friction.
1.
Coating can be done by physical methods or sputtering BUT for better bonding we should use the CHJEMICAL VAPOUR DEPOSITION where gas like TiCl4 & CH4 is reached on hot surface about 650*c.
2.
Multilayer coatings can also be used .The layer next to TiC which gives stable diffusion barrier(C leaving prevented) and outer layer TiN gives low interface friction.
3.
Coated carbides are more brittle than carbides but used when crater is to be removed.
FUTURE POSSIBILITIES:
From the above discussion it is considered that continuous interest in developing new cutting tools may have following new ideas: 1. Thermo-mechanical treatments to produce textural hardening. 2. Internal oxidation to produce very small(10 nm)hard particles that strengthen by precipitation or dispersion hardening. 3. Directional solidification of cast tool materials& casting techniques that eliminate the embrittling action of micro shrinkage cracks. 4. Application of cooling techniques to produce materials of very fine grain size approaching amorphous structure.
It is seen that there are many exciting new possibilities for further development in cutting tool materials.