A well-designed runner and gating system is very important to produce good quality die castings by providing a homogenous mould filling pattern. Flow analysis of the component is done in order to visibly analyse the cavity filling process. In this study, a Commutator End (CE) bracket, a cold chamber die casted product was chosen. Initially when the component was casted numerous defects such as Cold shuts, Misrun, Shrinkage porosity and Gas porosity were found. This in turn led to rejection of number of components. In order to improve the quality of the castings produced, the gating system was changed from the existing flat gate to modified spoon fed gate. The component was designed using Pro-Engineer and flow analysis was carried out using Rotork Flow 3D Software. The process parameters like metal temperature, fill velocity and filling time are considered for optimizing the process. Quality assessment for the die casting parts was made by microstructure analysis.
The main objective of this paper is to improve the productivity of a carburetor production processes using lean manufacturing technique. The current system of the carburetor production process has been mapped using electronic Value Stream Mapping (eVSM) tool which is a lean manufacturing tool and the wastages in the current system are identified. Then future state was drawn by using eVSM tool which has an enhanced process ratio by decreasing maximum possible waste in the production process. The current and future state of the carburetor production has been created as model and simulated using Arena software. The simulation shows a significant decrease in Non-Value added time and production lead time, thereby indicating increase in productivity and better work flow in production processes.
The computer aided tools and recent developments of engineering, emphasizes the importance of bringing manufacturing process into early stage for product and process design. The implied significance is that it becomes vital to reduce cost of product by extensive use of CAD tools for product formation without actually building the product. In this paper, CAD tools are used to design an extrusion die for bolt ejector pin. In this paper, the extrusion die used to produce the pin is modeled using Pro-E, a CAD tool. Then, the die is analyzed for the maximum extrusion load condition using ANSYS software, a Finite Element Analysis simulation (FEA) tool. The simulation results are compared with yield stress of material. After the die has been designed, the pin was extruded using the die. In order to evaluate the strength of extruded pin, the pin was also modeled and analyzed using ANSYS tool where it was found to be safe for its maximum ejection load condition.Keywords:Extrusiondiedesign,ejectorpin,Computeraidedmodelling(CAD),FiniteElementAnalysis(FEA).
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