- Open Access
- Authors : Sri Harsha R , Ch. Hemanthkumar , B. D. Y. Sunil
- Paper ID : IJERTV10IS060379
- Volume & Issue : Volume 10, Issue 06 (June 2021)
- Published (First Online): 01-07-2021
- ISSN (Online) : 2278-0181
- Publisher Name : IJERT
- License: This work is licensed under a Creative Commons Attribution 4.0 International License
Quality Investigation of A Ring Part of Aero Engine
Sri Harsha R1, Ch. Hemanthkumar2, B. D. Y. Sunil3
1,2UG Student Department of Mechanical Engineering, institute of Aeronautical Engineering, Hyderabad, Telangana, INDIA 2Associate Professor & Head, Department of Mechanical Engineering, Institute of Aeronautical Engineering, Hyderabad, Telangana, INDIA
Abstract:- In every manufacturing industry is quite common that deviations do occur in the process of manufacturing the parts or components. If every deviated part is scrapped then the company will shut down due to loss. At this point quality department plays a major role in manufacturing industry to identify the deviation, rectify the deviation and correct the manufacturing process so that the same deviation is not raised in future. So quality department is mainly categorized into quality assurance, quality control and quality engineering. Every department has its own importance in a manufacturing industry. The summary of the role of quality control and quality assurance department is that to identify deviation in manufactured product, Find out the root cause of the deviation, rectify the deviation and see to that same deviation is not raised in future.
Quality assurance (QA)/quality control (QC) department is responsible for ensuring the quality of products and services produced by their company. They oversee the manufacturing of products and they are involved in every stage of making a product from development and manufacturing to packaging. The Material Review Board (MRB) usually finds its dealing with product nonconformity caused by all sorts of evidence of poor design management. The main target of MRB is to reduce rejections and thereby reducing the loss of the company, to do so they have to find out the root cause of the defect and workout on the Root Cause Corrective Action (RCCA) that has to be implemented on the part so that the manufacturing design of the part satisfies the blueprint of the part. Based upon the RCCA the MRB takes decision whether the part has to be done rework, eNMS, scrap. The present project deals with the analysis and RCCA of ring part of an aero engine.Ordinarily, estimations were taken outwardly utilizing hand devices or an optical comparator. Notwithstanding, these instruments require critical time and have restricted precision. Then again, anorganize estimating machine (CMM) measures the stature, width, and profundity of the part utilizing coordinate handling innovation. Moreover, such machines can consequently gauge the objective, record the deliberate information, and acquire GD&T estimations. A facilitate estimating machine (CMM) is either a contact model that utilizations contact tests, a circular item used to perform estimations, or a non- contact model, which utilizes different techniques like cameras and lasers. A few models intended for the auto business can even quantify targets bigger than 10m (30 ft) in size.
The upside of the arrange estimating machine (CMM) is that it can quantify things that are hard to gauge with other estimating machines with high exactness. For instance, it is hard to quantify the three-dimensional directions of a particular point (opening, and so on) from the virtual beginning with a hand device like a caliper or micrometer. Likewise, estimation utilizing virtual focuses and virtual lines and mathematical resistances are troublesome with other estimating machines, however can be estimated with a 3D CMM machine. Regularly, most CMMs are scaffold or gantry-types as found in the graph. The circular contact point appended to the tip of the test is applied to the article on the stage, and the facilitate values in three measurements (X, Y, Z) are indicated and estimated.
It is primarily utilized for three-dimensional estimation of kicks the bucket, for example, car parts and different mechanical parts, three-dimensional items like models, and estimation of contrasts from drawings.
Inner Diameter unclear surface after honing operation
Part number selected for study
Last manufacturing process stage where the Problem is generated
Process stages where the problem is inspected currently
– Plateau Honing, Final Inspection
Fig 6.1.1 OK Part without Inner diameter unclear surface
Fig 6.1.2 Defective part with Inner diameter unclear surface
From Process Mapping & FMEA the following SSVs are identified and listed below
Table 6.1.2 Suspected sources of variations
Defect Concentration Chart
Concentration Chart is used to find out whether Inner Diameter unclear surface is concentrated in a particular region or can come at multiple locations (For initial investigation)
Fig 6.1.4 Defect Concentration
Conclusion: Since Inner Diameter unclear surface observed at Top, Center & Bottom places of the Component. So, decided to study at all locations.
Table 6.1.3 Selection of Tools
PC Paired Comparison, PPS Product/Process search, CS Component search MCS Modified Component search
MVA Multivari analysis VS Variable search, FF Full factorial, CC Concentration chart
Inner Diameter size from Fine Boring
Table 6.1.4Inner Diameter size from Fine Boring
6 Nos BOB & WOW parts were selected
After arranging in ascending order Count = 0
Conclusion – Since count = 0, the parameter Inner diameter size at fine boring operation is not creating the problem.
Inner Diameter Taper at Fine Boring operation
Table 6.1.5Inner Diameter Taper at Fine Boring operation
6 Nos BOB & WOW parts were selected
After arranging in ascending order Count = 0 Conclusion – Since count = 0, the parameter Inner diameter Taper at fine boring operation is not creating the problem.
Inner diameter ovality at fine boring operation
Table 6.1.6Inner diameter ovality at fine boring operation
6 Nos BOB &WOW parts were selected
After arranging in ascending order Count = 7 Conclusion – Since count > 6, the parameter Inner diameter ovality at fine boring operation is creating the problem.
Concentricity at fine boring operation
Table 6.1.7Concentricity at fine boring operation
6 Nos BOB& WOW parts were selected
After arranging in ascending order Count = 12 Conclusion – Since count >6, the parameter Concentricity at fine boring operation is creating the problem.
Tool used: Better Vs Current
Data collection: B condition will be with process improvement &C condition will be without process improvement.
Here B condition & C condition can be alternated. The changes implemented in the process can be reversible.
Table 6.1.8B Condition
Table 6.1.9 C Condition
By reducing clearance from 0.050 to 0.030 mm between skirt diameter and bottom locator at fine boring operation
Fig 6.1.5By providing taper angle 25Â° top locator at fine boring operation
Provided Top locator with taper angle 25 degrees
Fig 6.1.6 Reduced bottom locator with skirt diameter clearance from
0.050 to 0.020
RESULTS AND DISCUSSIONS
The purpose of this research paper is accomplished by identifying a deviation in the part using CMM machine during anufacturing process of a component then by properly performing RCCA (root cause corrective action) we got to know what is the root cause of the deviation i.e. tool worn. So, the tool has been corrected by modifying its parameters of use as a result the parts which are manufactured in future will not get same deviation raised. The corrected tool is used to rework the part so that it is not rejected and also matches the blueprint of the part. This is the procedure done in a regular manufacturing industry to reduce the scrap and reduce the loss of the company and thereby increasing the profits of the company.
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