cold forging process and product development - case study
DESCRIPTION
Cold forging, Head type Valve Tappet Process improvement, reduction in rejection and waste by right engineeringTRANSCRIPT
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Process and Product Development
Valve Tappet Cold forging Process
Abdullah Ansari
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INDEX• Introduction
• Nature of Problem
• Existing Blank & Forging Die Analysis
• Cold Forging Standard
• Existing D2/d2 & l/d Ratios
• Corrective Actions
• Recalculations, Results Of Recalculations
• Trials & Decisions
• Previous Process & Revised Process
• Results with Revised Tooling & Conlusion
• Support During Development
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INTRODUCTION
The problem of head offsetting while cold forging of item R 708‐13 is observedin since new product development.
To avoid the same several corrective actions [short method] were initiated suchas using flat ejector etc. but effectiveness of the actions taken was not 100%satisfactory. The results were not consistent.
After all above it is concluded to analyze and re‐design of cold forging tooling &process.
While analyzing the same whatever the calculations, observations and theactions taken by undersigned are recorded here, which will be one guide line toattend this kind of problems in future.
A. T. ANASRI Date : 22.08.2000
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Nature of Problem
( Tappet R 708‐13 )While cold forging 1st stage Head Diameter of Tappet getting more offsets & not getting controlled after
several adjustments.
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Existing Blank & Forging Die analysis • .Size of Cold forging blank: Total Length = 85mmOuter diameter ( d ) = 12.5mm• .Size of cold forged part:Head diameter ( D ) = 30mmHead thickness = 5.5mmTotal length = 61mmOD of stem = 12.8 & 12.6mm• .Size of Cold forging Die:Length of die = 90mmLength of blank outside the die ( l ) = 30mm
( From flat face )
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Cold forging standard
Cold forging standard states that:D2/d2 and l/d should not exceed 3. Where 2 is ideal.
In our caseD = 30mmd = 12.5mml = 30mm
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D2/d2 = 302/12.52 = 5.76l/d = 30/12.5 = 2.40 By above calculations it is noticed that value D2/d2 is
exceeding the standard and l/d is almost in range. So we may conclude that above exceeding value is
affecting to forged head diameter offsetting.
In light of Cold Forging Standard Existing D2/d2& l/d ratios
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What to do now ???
Corrective action planned :
–Recalculate the die design as per coldforging standard. And manufacture thecold forging die as per new calculateddimensions.
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Recalculations as per Cold forging standard
D2/d2 = 2 ( as per standard )Hence D2/12.52 = 2D2 = 2 x 12.52
D = 17.67mm.‘l’ of ‘D’ will be 17.67x17.67x l x /4 = 12.5x12.5x30x /4
l = 15.01mm
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What Recalculations Indicating!!!
Recalculations indicating that the forging is not possible in one operation& it will need double operation. For second operation stepped blank willbe required, while first operation stepped blank will be produced.
For preparing stepped blank separate die isrequired
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Trials .
For trials stepped blank is prepared by machining. While trials forming punch is used.
Trials are taken with stepped blank on 22.08.2000Results found satisfactory in all aspects.Head offsetting is very low & will not create anydefect while head turning.
Dimensions are found consistent.Trials are successful.
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Way Forward.
Based on successful trials, die designed for first operation for preparing the stepped blank (cold forging 1st operation).
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# PREVIOUS PROCESS
Fig. Shows the
blank ready for
forging of R708‐
13 tappet.
85
12.5
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1 ‐ PREVIOUS PROCESS
Fig. Shows the
forging drawing of
R708‐13 tappet.
Previously this was
created in single
setting.
30 12.8
5
40
12.6
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# REVISED PROCESS
Fig. Shows the
blank ready for
producing
stepped blank
for forging of
R708‐13 tappet.
85
12.5
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1 ‐ REVISED PROCESS
Fig. Shows the
stepped blank
ready for finish
forging of R708‐13
tappet.
12.6 12.5
40
17.7
15
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30 12.8
5
40
12.6
2 ‐ REVISED PROCESS
Fig. Shows the finish
forging of R708‐13
tappet.
Now it is created in
second stage from
stepped blank.
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Die drawing for stepped Blank
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Results with revised tooling.
Implemented the new tooling & monitored for 1000nos forcold forging 1st & 2nd operation.
No problem while preparing stepped blank. I.e. 1stoperation.
No problem of head forming while 2nd operation.Improved consistency in dimensions while cold forging 2nd stage.
Setting time for cold forging is reduced.Minimizes rejection at cold forging drastically . Hence reduction in wastage.
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FINAL CONCLUSION.
The newly designed tooling is OK & Proven
for production.
05.11.2000
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Mr. V RamgopalMr. M. GANAPATHY
For Giving A Opportunity To Work On Such A Special Task.
Mr. S.C.SALVI & Mr. P.S.KULKARNI Team members
Acknowledgements