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Individual statistics project Submitted by: Chandra Prakash R Roll no: PGEXP/184

Statistical analysis of Yield Strength Variation In Cold rolled product leading to cracking at customer end.

1.0 Introduction Stattistics individual project was for analysis of day to event all around us it may be from industry or from suorrounding ,what I have did I have selected a recent problem faced by our Auto customer it mainly related to cracking of componenet during drawing stage ,so in my analysis I have found that variation in one of mechanical properties( yield strength) is the reason for cracking of component at Customer end.This case is from Cold Rolling Mill of Tata Steel. 1.1 About Tata Steel TATA STEEL is the largest private sector steel marketer in India. Presently, its Jamshedpur (India) Works has a crude steel production capacity of 10 million tonnes per annum. Tata steel is 8th Largest steel producer in the world .The company has been successful in maintaining its dominant position among key segments in the Indian steel market and has also established a significant presence in the international markets through both tie-ups with customers and mergers and acquisitions. The company is aiming at enhancing its domestic steel capacity to about 30 million tonnes per annum by 2020. 1.2 About Cold Rolling Mill

CRM complex has been commissioned at TATA STEEL works in the year 2000. The total output of the CRM complex consists of 1Mt of cold rolled and annealed products and 0.5 mtpa (Million Tonne Per Annum) of cold rolled and galvanized products. Hence, the total installed capacity of this

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unit is approximately 1.5 million tons per annum. The range of thickness and width of these cold rolled products are 0.2 to 3.2 mm and 800 to1560 mm respectively. The primary input material to the cold rolling complex is a hot rolled coil. The cold rolled products are broadly under the categories: Annealed coils, Galvanized coils, Cold rolled full hard coils. The cold rolled products from the CRM complex are designed to cater to various market segments such as construction, general Eng., automobile, white goods, packaging and others. Tata steel Process Flow

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Cold Rolling Mill Process Flow

Material Used at Customer End

Problem was in this material 4|Page

1.3 About Yield Strength YIELD STRENGTH a)Yield strength is the amount of stress at which plastic deformation becomes noticeable and significant. Fig.1 is an engineering stress-strain diagram in tensile test. Because there is no definite point on the curve where elastic strain ends and plastic strain begins, the yield strength is chosen to be that strength when a definite amount of plastic strain has occurred. For the general engineering structural design, the yield strength is chosen when 0,2 percent plastic strain has taken place. The 0.2% yield strength or the 0.2% offset yield strength is calculated at 0.2% offset from the original cross-sectional area of the sample (s=P/A). b)During yielding stage, the material deforms without an increase in applied load, but during the strain hardening stage, the material undergoes changes in its atomic and crystalline structure, resulting in increased resistance of material to further deformation. c)Yield strength is a very important value for use in engineering structural design. If we are designing a component that must support a force during use, we must be sure that
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the component does not plastically deform. We must therefore select a material that has high yield strength, or we must make the component large enough so that the applied force produces a stress that is below the yield strength. In contrast, the tensile strength is relatively unimportant for ductile materials selection and application since too much plastic deformation takes place before it is reached. However, the tensile strength can give some indication of the materials, such as hardness and material defects. INCLUDEPICTURE "http://www.tppinfo.com/web_pic/ode001.gif" \* MERGEFORMATINET

Fig.1 Stress strain diagram Complaints: Customer has reported cracking in material from certain lot of our supply. Our Analysis: We have did analysis with respect to process parameter & no abnormality was reported except we found that in crack material Yield strength is in upper limit of specification similar trend is found in other similar complaints . So we have analysed the yield strength data of Jan-12 Total data taken for 329 Coils

Mean: f x / n here, class 145-150 means 145 < data <=150

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n=329

Class 145-150 150-155 155-160 160-165 165-170 170-175 175-180 Sum Mean

Mid point(x) 147.5 152.5 157.5 162.5 167.5 172.5 177.5

frequency 14 18 35 68 71 44 79 329

f*x 2065 2745 5512.5 11050 11892.5 7590 14022.5 54877.5 166.801

Mean =54877.5/329=166.8 Mean is coming 166.8 with Minimum of 147 & maximum of 180 however specification limit at Plant is 145-180

Now n=329 which is odd so median class lies in (n+1)/2 = (329+1)/2=115 so median class will be 160-165

Class 145-150 150-155 155-160 160-165 165-170 170-175 175-180

Mid point(x) 147.5 152.5 157.5 162.5 167.5 172.5 177.5

frequency 14 18 35 68 71 44 79

f*x 2065 2745 5512.5 11050 11892.5 7590 14022.5

Cumulative frequency 14 32 67 135 206 250 329

So median Class is 160-165 Median =L+ (n/2- CF)*i/f L = Lower limit of the class that contains the median = 160 n = Number of numbers = 329 CF = Number of numbers before the class containing the median = 67 f = number of numbers in the class containing the median = 68
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i = class interval (size) =5 Median =160+ (164.5-67)*5/68=167.17

Mode: Here frequency of 175-180 class is maximum so modal class is 175-180

Mode=
l = lower limit of modal class f1 = frequency of modal class fo = frequency of class preceding the modal class. f2 = frequency of class succeeding the modal class h = size of class interval.

Class 145-150 150-155 155-160 160-165 165-170 170-175 175-180

Mid point(x) 147.5 152.5 157.5 162.5 167.5 172.5 177.5

frequency 14 18 35 68 71 44 79

l=175 f1=79 f0=44 f2=0(as last class is modal class ) h=5 Now putting all Mode= 175+(79-44)*5/(158-44-0)=176.53

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