28-08-2014, 04:35 PM
Six Months Industrial Training Report At Federal Mogul Goetze (india) Limited Bahaduegarh, Patiala
After doing my training in FMGIL, Bahadurgarh, Patiala. I felt the importance of training in the industry and its practical applications, when I was studying the theories of different concepts I was thinking how these all will be implemented. But after the training, I learnt how all these could be put in good use. It was the result of training only that I got to see the objects in real and practical use. During my training in FMGIL, I got chance to expose to the industry culture and work environment. In other words, these days of training in FMGIL were learning experienced all the way. These happen only due to co-operation of staff and the management who helped me in gaining whatever knowledge I have today about the production, management and quality assurance. In the end, I would like to conclude that the training is an essential part of the education programme. We should always pursue for the theoretical as well as the practical knowledge, both of which are must for the production of high building
1. Pouring speed: The main factor during casting of piston is the pouring speed, time taken. The pouring of metal in the die must be uniform throughout the pouring process and it must not be too fast not too slow. If the pouring is too fast then there is turbulence in the flow which causes ext rametal on the sides of the piston and cause shrinkage too and slow fluidity of metal in the die cause faster cooling of metal results in the solidification faster and the metal is not reach to all the die which causes shrinkage. By taking action on the pouring parameters the scrap is reduced to the average of 16%.
2. Die design: The other factor is the design of the dies. The design of blank of the piston is too much complex because of the design of the windows, skirt design etc. The design of the Die is accordance with the process feasibility and with requirement of the customers so we can’t afford the change in the design of the dies. 3. Gating system design: The other main factor that causes the design of the gating system which comprises of the Runner, Reservoir, sleeves and Runner. The main defect occurs on the skirt of the piston so we are main concern with the runner, reservoir and riser. The cause of the shrinkage is that metal is not provided after solidification so we increase the size of the runner and riser but this could not cause effect on the shrinkage so with concern with the supervisors and employees we decreased the size of the runner riser, runner and the thickness of the reservoir which cause the drastic decrease in the scrap of the piston to about 10% from 16% average. 4. Temperature of the melt: The other factor on which shrinkage defect is the temperature of the melt. The current temperature on which castings are made out is in the range 760-7800 C. We increase the temperature of the melt to the 790-8000 C. This cause in increase in the 87 feeding time of metal in the die by which the metal reaches to every part of the die which considerably reduces the rejection rate to 8.5%. 5. Degassing/washing: The other factor is the washing of melt before the actual casting is done with the help of the fluxes GR 6512 and Coveral 11 mixed with chlorine and argon gasses. At the earlier times the time of the washing is 8-10 minutes which is not sufficient enough to remove the whole of the gas present in the melt so we increase the washing time of melt to 10-12 minutes which helps in proper ejection of the gasses from the melt. This ultimately reduced the rejection rate to 7%. 6. Foundry equipment availability: In foundry there is shot blasting machines which are used to clean the parts of the dies. Eventually in earlier times the CT-100 dies are not clean regularly by which the air vents are blocked so there is no passage of ventilation of air results in blow hole created in the piston blanks. By implementing various ways with the discussion with the shop seniors now one die is cleaned regularly once a week, by these all the air passages are opened by which whole of the air is removed from the die cavity during pouring so there is no such condition of having the blowholes in the piston blanks. By implementing this suggestion the scrap has reduced to 6.3%. 7. Machine line availability: As we discussed earlier that there are several types of casting machines available in the shop like DCM 3, DCM 9, DCM 13, DCM 17 etc. earlier the Ct 100 pistons are formed in the DCM 3 machines which have double cavity the major problem in this is that after pouring in first die the temperature of melt in the scoop is feel down and secondly there is no perfect cooling of metal in the second die. So by concerning with the heads and supervisors we take the decisions that CT-100 pistons are not made in the DCM 3 machines and are made out in the single cavity machine which enhances the quality of the pistons to some extent. Finally by this suggestion the scrap has reduced to average of 5.8%.
After doing my training in FMGIL, Bahadurgarh, Patiala. I felt the importance of training in the industry and its practical applications, when I was studying the theories of different concepts I was thinking how these all will be implemented. But after the training, I learnt how all these could be put in good use. It was the result of training only that I got to see the objects in real and practical use. During my training in FMGIL, I got chance to expose to the industry culture and work environment. In other words, these days of training in FMGIL were learning experienced all the way. These happen only due to co-operation of staff and the management who helped me in gaining whatever knowledge I have today about the production, management and quality assurance. In the end, I would like to conclude that the training is an essential part of the education programme. We should always pursue for the theoretical as well as the practical knowledge, both of which are must for the production of high building
1. Pouring speed: The main factor during casting of piston is the pouring speed, time taken. The pouring of metal in the die must be uniform throughout the pouring process and it must not be too fast not too slow. If the pouring is too fast then there is turbulence in the flow which causes ext rametal on the sides of the piston and cause shrinkage too and slow fluidity of metal in the die cause faster cooling of metal results in the solidification faster and the metal is not reach to all the die which causes shrinkage. By taking action on the pouring parameters the scrap is reduced to the average of 16%.
2. Die design: The other factor is the design of the dies. The design of blank of the piston is too much complex because of the design of the windows, skirt design etc. The design of the Die is accordance with the process feasibility and with requirement of the customers so we can’t afford the change in the design of the dies. 3. Gating system design: The other main factor that causes the design of the gating system which comprises of the Runner, Reservoir, sleeves and Runner. The main defect occurs on the skirt of the piston so we are main concern with the runner, reservoir and riser. The cause of the shrinkage is that metal is not provided after solidification so we increase the size of the runner and riser but this could not cause effect on the shrinkage so with concern with the supervisors and employees we decreased the size of the runner riser, runner and the thickness of the reservoir which cause the drastic decrease in the scrap of the piston to about 10% from 16% average. 4. Temperature of the melt: The other factor on which shrinkage defect is the temperature of the melt. The current temperature on which castings are made out is in the range 760-7800 C. We increase the temperature of the melt to the 790-8000 C. This cause in increase in the 87 feeding time of metal in the die by which the metal reaches to every part of the die which considerably reduces the rejection rate to 8.5%. 5. Degassing/washing: The other factor is the washing of melt before the actual casting is done with the help of the fluxes GR 6512 and Coveral 11 mixed with chlorine and argon gasses. At the earlier times the time of the washing is 8-10 minutes which is not sufficient enough to remove the whole of the gas present in the melt so we increase the washing time of melt to 10-12 minutes which helps in proper ejection of the gasses from the melt. This ultimately reduced the rejection rate to 7%. 6. Foundry equipment availability: In foundry there is shot blasting machines which are used to clean the parts of the dies. Eventually in earlier times the CT-100 dies are not clean regularly by which the air vents are blocked so there is no passage of ventilation of air results in blow hole created in the piston blanks. By implementing various ways with the discussion with the shop seniors now one die is cleaned regularly once a week, by these all the air passages are opened by which whole of the air is removed from the die cavity during pouring so there is no such condition of having the blowholes in the piston blanks. By implementing this suggestion the scrap has reduced to 6.3%. 7. Machine line availability: As we discussed earlier that there are several types of casting machines available in the shop like DCM 3, DCM 9, DCM 13, DCM 17 etc. earlier the Ct 100 pistons are formed in the DCM 3 machines which have double cavity the major problem in this is that after pouring in first die the temperature of melt in the scoop is feel down and secondly there is no perfect cooling of metal in the second die. So by concerning with the heads and supervisors we take the decisions that CT-100 pistons are not made in the DCM 3 machines and are made out in the single cavity machine which enhances the quality of the pistons to some extent. Finally by this suggestion the scrap has reduced to average of 5.8%.