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PROBLEM SOLVING

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

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PROBLEM SOLVING

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  1. 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.

  2. Picture shows Metal Filling at various intervals The colour scale shows the temperature at each location

  3. Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available Isolated region

  4. Picture shows the possible Shrinkage area This defect location exactly matches with customer complaint Shrinkage location

  5. PROBLEM SOLVING • Corrective Action • Gating changed • Feeder size increased and number of feeders reduced 2

  6. Picture shows Metal Filling at various intervals The colour scale shows the temperature at each location

  7. Picture shows Solidification at various intervals The colour scale shows the % of Liquid metal available

  8. Picture shows the porosity locations There is no defect inside the casting

  9. Finding after implementation of this method Hotspot moved to feeder and there is no defect noticed inside the casting. Yield also increased by 10% 100% UT o.k and mold erosion problem eliminated.

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