MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L PROBLEM SOLVING OLD METHOD Component Name : Gear Stay Component weight : 182Kgs Number of Castings per Mold : 1nos. Total Good Casting wt : 182Kgs Total Pouring wt : 310kgs Yield : 58.5% PROBLEM DESCRIPTION Component getting rejected in Ultrasonic testing for back wall echo loss.
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MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
PROBLEM SOLVINGOLD METHODComponent Name : Gear StayComponent weight : 182KgsNumber of Castings per Mold : 1nos.Total Good Casting wt : 182KgsTotal Pouring wt : 310kgsYield : 58.5%
PROBLEM DESCRIPTIONComponent getting rejected in Ultrasonic testing for back wall echo loss.
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
Isolated region
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows the possible Shrinkage areaPicture shows the possible Shrinkage area
Shrinkage locationThis defect location exactly matches with customer complaint
This defect location exactly matches with customer complaint
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Corrective Action• Gating changed• Feeder size increased and number of feeders reduced 2
PROBLEM SOLVING
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
Picture shows Metal Filling at various intervalsThe colour scale shows the temperature at each location
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
Picture shows Solidification at various intervalsThe colour scale shows the % of Liquid metal available
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Picture shows the porosity locations
There is no defect inside the casting
Picture shows the porosity locations
There is no defect inside the casting
MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d
Finding after implementation of this method
1.Hotspot moved to feeder and there is no defect noticed inside the casting.2.Yield also increased by 10%3.100% UT o.k and mold erosion problem eliminated.
Finding after implementation of this method
1.Hotspot moved to feeder and there is no defect noticed inside the casting.2.Yield also increased by 10%3.100% UT o.k and mold erosion problem eliminated.
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