Project guide: R.

Asokan
Ahmed Fazil B. (30507101004) George Mathew (30507101023) Marwa Hussain (30507101046) Mathew Jacob (30507101047)

Designing the turning fixture to machine the component called CASE ASSEMBLY PLENUM used in GARRETT TPE 331-5 engine in Dornier 228 aircraft.

The Case Assembly important component Requires close tolerance and accuracy. Improper machining leads to rejection.
The main scope of the project is as follows: Reduce the rejection rate Decrease the production time To eliminate operator fatigue

A fixture is a device for locating, holding and supporting a workpiece during a manufacturing operation. Fixtures are essential elements of production processes .

 Locators
Clamps Supports Fixture body

The CASE ASSEMBLY PLENUM are being rejected due to : The geometrical tolerances . Dimensional tolerances are not conforming within the band while machining from operation number 625 to 750.

In operation 630. Diameter 15.220^0.005 is not achieved. Perpendicularity of 0.001 with respect to datum-A-is brought within a tolerance band. Run out of 0.005 with respect to the location and the butting is not confirming within the tolerance band.

In operation 655/660. Diameter 15.234^0.003 is not achieved Perpendicularity of 0.001 with respect to datum A- is not within the tolerance band. Run out of 0.005 with respect to the location and the butting is not confirming within the tolerance band.

In operation 690. Diameter9.84^0.005 Is not achieved Flatness of 0.005 with respect to datum-A- is not within the tolerance band Run out of 0.005with respect to the location and buttingis not confirming within the tolerance band.

In operation 730 Faltness of 0.005 is not within the tolerance band Run out of 0.003 with respect to the datum-Aand datum B-is not confirming within the tolerance band.

 Bell-mouth

,face out & runout 255.5mm of stator ring at operation 40 & 60 Bell-mouth, face out & run out problem of PTAE NGV turbine of 327.0mm at operation 060 High rejection rate & production time is more in case assembly plenum of GARRET project Ring locating outer nozzle AX58217 flatness of 0.05mm is not achieved Integral gear box of 026010758 position of 8 holes is exceeding 0.02mm

 Problems

in each category were ranked, so that when solved, they should add value and contribute to organisations goal. This was done using following criterias: Productivity, Quality, Cost saving, Approximate reduction in lead time, & investment.

The problem we have selected for further study and analysis is the high rejection rate and production time. After conducting the various necessary procedures our team has been successful in reducing the production time the details given below shows how we went about it . We are unable to machine top face. Difficulty in top drilling operations. This set-up causes difficulty in machining of internal diameter. After removing top clamp we will get Ovality.

 Heavy vibration
Difficulty in

balancing. Overall performance of the engine is reduced.

 Loading

pattern for carrying out operation 630 with 0.7-1.0mm face-out

 EXISTING

SNAG

PART NAME : CASE ASSEMBLY PLENUM PART NO. : 3102613-2 PROJECT : GARRETT DESIGN COMPLEXITY : COMPLEX A. YEILD : 31% VALUE OF PART : Rs.300000

 Improper processing

is a prominent factor of

the problem. Problems occurred in Operation 625 to 750 during welding and heat treatment process. Face out of o.7-1.omm observed in butting face of Operation 625. This face out is transferred while skimming as well as to the Operation 630. Operations 625-750 are carried out on different work centers that lead to unnecessary movement of parts.

 Each

operation requires fixture setting, tool setting, job setting. Due to welding operation in previous operation part contains 0.7 mm face out and ovality. Machine consistency. Part to be moved to varies machines for each operation. Fixtures are too big operator gets fatigue while handling. Condition of the machine like vibration, rigidity etc.. Speed, feed and depth of cut.

Solution 1 Clamping the part with the top clamping plate. Difficulty observed: To machine top face and bottom diameter. During the top drilling operations.

Solution 2 Removing half portion of the center pillar to carry out top facing and drilling operations. Difficulty observed: To carry out inner diameter machining. Clamping of part rigidly for the drilling operation .

Solution 3 This the only solution that could match up with the expected or desired success rate. Introduced skimming operation before operation 625 on both sides, reducing the faceout from 0.7mm to 0.01mm. Designed the fixture for the operation 655,660,730, and 750 which will be done in a single set-up. Fixture centre bungs diameter is reduced and clamped 3 segments at the circumference such that extending beyond the center bung diameter and turned the segments to the required diameter to locate the part.

 Special

clamps were designed to suit the shape of the side boss that help in clamping the part rigidly and have the clearance for the side welded boss. A location pin, which facilitates of easy location of part.The location pin also acts as reference for drilling holes.This is also known as poke yoke. Fixture is square hence we made centre hole perfectly round. 12 holes of different diameter at 45 degree, for weight reduction. This reduces operator fatigue while loading and unloading of fixture.

 Toshulin VTL

prefered for machining which is of vertical turn-mill CNC machine,where turning as well as drilling operations can be done. Movement of part to various machines is avoided with this. It contributes to drastic reduction in rejection rate and production time. Thus the solution 3 was selected for the particular problem.

 With

this fixture (2) Parts have been produced, all parts have been perfectly conforming geometrical tolerance, without any deviations. Along with this production time has been considerably reduced.

 Fixture material

=Mild Steel Tensile strength=400N/mm square Percentage of minimum elongation=25 mm Maximum yield stress=285N/mm Hardness of steel=137

data available: Speed of bed(N) =250rpm Feed rate (t) =0.1m/s Depth of cut (b) =0.2 Material constant for mild steel =98 Hardness of mild steel Steel(HB) =137 Maximum yield stress of mild steel=285 N/min

cutting speed: Cutting speed=3.14*N*D/60 N=250 D=415 Therefore,cutting speed=5430 m/s approx.

cutting force: Cutting force=c*t*b=1.96 FACTOR OF SAFETY(FOS): Factor of safety=Maximum yield stress/cutting force+weight of part

PREVIOUS PROCESS TIMINGS

OPERATION No. OPERATION 625 OPERATION 630 OPERATION 655/660 OPERATION 690 OPERATION 700 OPERATION 730 OPERATION 750 SET-UP TIME in HRS 3 3 3 3 3 3 3 UNIT TIME in HRS 6 8 15 15 15 15 30

21

104

TIMINGS FOR OUR NEW PROCESS

OPERATION No. SET-UP TIME in HRS 3 UNIT TIME in HRS 6

PERCENTAGE REDUCTION IN TIMINGS

OPERATION 622

OPERATION 625

3
3 3

6
40 17

(New time/ Old time)* 100 (81/125)*100=64.8% 100-64.8=35.2%

OPERATION 630 OPERATION 650

12

69

 Due to reduction

in Rejection rate Rs.30 Lacs net savings per annum . Process made simple. Cycle time is reduced 35.2%. Movement to debur and inspection after every operation is avoided.

 Quality of

components improved. Component delivery as per schedule. Operators fatigue is reduced. Operators morale is boosted. Vibration of an engine eliminated. Balancing of the component is easy. Overall performance of the engine is improved

 Reduced

rejection time. Reduced cycle time. Scheduled delivery is achieved. Movement of part is avoided. Operator fatigue is reduced. Yield 100%. Process made simple and quicker.

Thus ,it is found that the above results obtained after implementation of the designed fixture has proved to achieve the objectives of the project.