mudhra presentation pdf

8/14/2019 Mudhra Presentation PDF

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By

Srikrishna.A.SSrikanth. R

Sriram. CFinal Year Students, B.E. Mechanical, Jeppiaar Engg. College


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Acquaintance with industrial environment and identification of

required skill sets.

Hands-on learning of the functioning of various machines and

recognition of application of theoretical concepts.

Study of fundamental theories and concepts of metal pressing.

Overviews of basic principles of die and punch design.

Detailed study of any one metal pressing process.

Project Presentation - Jeppiaar Engineering College


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The Mudhra Group is a leading manufacturer of

meticulously engineered, precision metal components

which caters to a wide clientele range in the automotive

industry.

Technical Partners :

Feintool Technologie, Switzerland

Trelleborg Rubore, Sweden. Only company in India that has the latest generation of

Fine-blanking systems in place.



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Specialising in manufacture of :

Pad Backing plates (Disc Brakes).

Shims (Disc brake, rubberized steel).

Push-rods (Drum brakes, Auto-adjuster mechanism).

Commercialised tooling for domestic customers.

New product development capabilities :

Tooled-up sample in 4 weeks.

CNC wire-cut sample in less than a week.

ISO/TS16949 and QS9000 CKPMG certifications.



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PRODUCT AUTOMOTIVE SECTOR CLIENTS

PAD BACKING PLATES

1. Maruti Suzuki full range2. TVS - Fiero motorcycle.3. Tata full range.4. Fiat full range

PUSH-RODS

1. Tata.2. Toyota.3. Fiat.4. Mahindra Scorpio.

5. Maruti Omni.

SHIMS

1. Tata2. Ford.3. Honda.4. Maruti.5. Mahindra.



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Brakes India, Sundaram Brakes,

Rane Brakes,

Sundaram Fasteners,

Aztec Auto, Turbo Energy,

Axles India,

Wheels India,

Amalgamations Repco, Audco (L&T),

Ashok Leyland.



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PPAP is a Part approval process conceived and formulated byDaimler Chrysler Corp., Ford Motors and GM.

Defines the generic requirements for production part approval.

Purpose:

To determine if customer requirements are properly

understood.

To ascertain the potential of the mfg. facility to meetsustainable production rate demands.



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Section 1: General submission of PPAP

Section 2: PPAP Requirements: 18 clauses

Section 3: Submission to customers.

Section 4: Levels of evidence ( 5 Levels )

Section 5: Part submission status Approved

Interim Approval

Rejected

Section 6: Record Retention



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An FMEA can be described as a systemized group of

activities intended to:

Recognize and evaluate the potential failure of a product

or a process and its effects, Identify actions which could eliminate or reduce the

chance of the potential failure occurring, and

Document the process. It is complementary to the design

process of defining positively what a design must do to

satisfy the customer.



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Design FMEA Living document initiated before or at design concept finalization

Continually updated as changes occur or additional information is

obtained

Emphasis on preventive design control.

Process FMEA

How can a process, function, facility, or tooling fail ?

What effect will process, function, facility, or tooling failures have on

the end product (or customer) ?

How can potential failures be eliminated or controlled ?

Suited for manufacturing processes.



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Estimation of feasibility ofSMET (Single Minute Exchange of Tool)



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In all, 150 tools dimension were recorded andhave been tabulated in the detailed report.

Tabulation done category wise.

This data would help the technicians to perform aSMET feasibility analysis.



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Number of active working hours of machine in a 5-hour duration of production recorded over a periodof 5 days.

Time: 10:00hrs to 15:00hrs.

Totally, 38 machines were monitored thrice anhour for 5 hours daily.

Results plotted as a chronological graph in thedetailed report.



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The objective of Phase III was to study the basic principles of die and

punch design with a special focus on blanking operation.

Overview of stamping process.

Types of stamping.

Functions of die and punch.

Hardening and heat-treatment processes.

Clearance between die and punch.

Shearing deformation and sheared edge study of Blanking operation.

Blanking force calculation.



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In any stamping tool, there are two principal parts called Punchand Die. The punch is a male part which, during stampingoperation, slides into a cavity (female part) after penetrating

the metal. This cavity is called the die.

Both punch and die are made of Tool steel

Separation between the die and punch is called as Clearance. A stripper is used to hold down the sheet metal firmly as the

punch penetrates it.



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The primary choice of material for Punches and Dies is tool-steel.

Tool steel refers to a variety of carbon and alloy that areparticularly well-suited to be made into tools.

Tool steel carbon content: 0.7% - 1.4%

Manganese content is kept to a minimum to resist cracking.



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Based on the sheet-metal properties, a steel variety possessing sufficiently high RockwellHardness Number (RHN) is chosen. E.g.: for Mild Steel sheet metal, the recommendedsteel RHN is from 60-62.

Then, through carburizing process, Carbon is added in measured quantities so as toachieve a 1.5% - 2% concentration in the steel.

Subsequently, the steel is heated to 1100C, which causes a recrystallisation of the grainstructure of the steel resulting in new stress-free grain geometry. This causes core-hardening of the steel.

Now, the steel attains the required level of hardness and toughness. Further, the steel is

heated and air-annealed in order to soften it if so required.



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Distance of separation between the Die and Punch.

Crucial for obtaining very high blanking accuracy.

For mild steel, the recommended clearance range is 15%-20%

of sheet thickness.

For harder steel variants, the clearance ranges from 20% to

30% of sheet thickness.



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Blanking involves

a cutting or

shearing process

of the stamping

stock using shear

deformation



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Maximum blanking force must be calculated beforehand in order

to determine the capacity of the press machine needed to perform

the blanking.

P = t * L * K1 * B

P = Blanking Force (kg-f)

t = Metal thickness (mm)

L = Total Length of all cuts (mm)

K1 = Correction Factor (0.8~1)B = Tensile Strength of metal (kg-f/mm

2)



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