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    Tool Room

    Uploaded by

    Subramanya Seeta Ram Prasad
    1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

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    © All Rights Reserved
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    Tool Room

    Uploaded by

    Subramanya Seeta Ram Prasad
    196 views13 pages
    1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

    Original Description:

    kaizan

    Original Title

    tool room

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    1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    196 views13 pages

    Tool Room

    Uploaded by

    Subramanya Seeta Ram Prasad
    1) The document discusses various tool room countermeasures to prevent frequent tool breakage and wear. It describes issues like piercing punch breakage, die backplate breakage, and knife wear being addressed by modifications like adding radii, increasing thickness, and applying coatings. 2) Conversions of machines are described to make better use of capacity, like converting a D08N o-ring machine to a D08E model and a 4C bush extrusion machine to a D08E model. Modifications like adding pin guides and changing carriers are mentioned. 3) Other countermeasures included adding fork support during pin assembly, providing entry steps to bush pilots to improve alignment, and implementing a gauge plate to more easily

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 13

    TOOL ROOM

    THEME : To Prevent frequent brakeage of piercing


    punches

    Before

    AFTER

    Breaking at
    this point

    PHYSICAL PHENOMENON : frequent breakage of piercing punches in 08E HMSI OP


    (20 Occ / month).

    Analysis :

    Countermeasure : -

    W1: piercing punch breakage


    W2:.load on shank area
    W3: sharp corner at shank taper area.
    W4: weak at sharp corner.

    By providing smooth radius at shank


    taper area so that punch is
    strengthened.

    THEME : To Prevent breakage of die back up plate

    Before

    101/102 DIE BACK PLATE 30mm


    THICKNESS

    AFTER

    101/102 DIE BACK PLATE 40mm


    THICKNESS

    PHYSICAL PHENOMENON : frequent breakage die back up plate in


    101/102 OP (2 times)
    Analysis :

    Countermeasure : -

    W1: die back up plate breakage

    By increasing the thickness of die back


    up plate from 30mm to 40mm, hence
    back up plate is strengthened.

    W2: not withstanding the load.


    W3: less thickness

    THEME : To Prevent frequent tool change due to


    wear out

    Before

    AFTER

    BUSH FORMING M/C (KBD) KNIFE NON


    COATED

    BUSH FORMING M/C (KBD) KNIFE ALCRONA


    COATED

    PHYSICAL PHENOMENON : frequent change of tool due to wear out .


    (every 20kgs).
    Countermeasure : Analysis :
    W1: tool wear out
    W2: low hardness

    Knife working area is coated with


    Alcrona, hence surface hardness has
    increased.

    THEME : To Prevent frequent TOOL CHANGE DUE


    TO WEAR OUT

    Before

    KBD L . H & R .H TOOLS

    AFTER

    KBD L . H & R .H TOOLS WITH CARBIDE TIP

    PHYSICAL PHENOMENON : frequent change of tool due to wear


    out (500kgs ).
    Analysis :
    Countermeasure : W1:tool wear out.
    W2:low hardness.
    W3:tool material didn't support to get
    high hardness.

    Carbide insert brazed at working area,


    hence working area got good hardness.

    THEME : To prevent operator skill in clamping tool

    Before

    AFTER

    PHYSICAL PHENOMENON : clamping tool with non standard clamps


    getting loose in running causes tool break down.
    Analysis :
    W1:tool break down due to non
    standard clamps.

    Countermeasure : Provided direct clamping by providing


    spacer and T clamp screw holes.

    THEME : To prevent bush miss


    alignment

    Before

    AFTER

    PHYSICAL PHENOMENON : to prevent bush pilot breakage due to


    miss alignment .
    Analysis :
    W1:bush pilot breakage.
    W2:miss alignment between bush and
    pilot.
    W3:less clearance to align.

    Countermeasure : Provided entry step to bush pilot , hence


    it got 1mm per side clearance to align
    bush with pilot.

    CONVERSION OF D08N-O-RING
    ASSEMBLY M/c to D08E MODEL
    BEFORE

    AFTER

    As 8E Model order has increased and 8N O Ring M/C has less order M/c
    has converted to 8E
    ALL TRACKS
    CHANGED

    PIN ANVIL AND BUH


    ANVIL

    PIN GUIDE
    ADDED

    PIN CARRIER
    HOLDER
    CHANGED

    Before

    AFTER

    Fork support is increased up to pin assembly stage.

    Provided pin guide to assemble pin easily.

    Pin carrier holder changed to use common pin carrier for all
    machines .

    CONVERSION Of 4C SOLID BUSH EXTRUSION


    M/c to D088 MODEL PROPOSED & TAKEN TRAIL
    Before

    AFTER

    As 4C Model order is less than M/C capacity, in order to use M/C in ideal time it is proposed to
    convert it to 88 model

    Before

    4th PUNCH

    AFTER

    4th KO
    PUNCH

    4th DIE

    4th PUNCH
    HOLDER

    4th KO PUNCH HOLDER


    COLLET

    4th PUNCH

    4th KO
    PUNCH

    4th DIE

    4th PUNCH
    HOLDER

    4th PUNCH HOLDER


    COLLET

    THEME : Difficulty in checking blanking


    punches

    BLANKING PUNCHS CHECKING


    GUAGE PLATE

    PHYSICAL PHENOMENON : difficulty in checking blanking


    punches.
    Analysis
    :
    Countermeasure : W1: difficulty in checking blanking
    punches
    W2: difficulty in checking profile
    accurately

    Implemented gauge plate to check


    blanking punches easily and accurately.

    Thank You

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