Quality Investigation of A Ring Part of Aero Engine

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.

INTRODUCTION

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.

MAIN CONTENT

Analysis Phase

• Problem Statement

  Inner Diameter unclear surface after honing operation

• Part number selected for study

  2H.008.01.0.07

• Last manufacturing process stage where the Problem is generated

  • Fine Boring

• Process stages where the problem is inspected currently

– Plateau Honing, Final Inspection

GOOD PART

Fig 6.1.1 OK Part without Inner diameter unclear surface

DEFECT PART

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

1. 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.

2. 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.

3. 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.

4. 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.

Improvement Phase

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 25° 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.

REFERENCES

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   ( G U M ) 1st edn. (Joint Committee for Guides in Metrology (JCGM), Bureau International des PoidsetMesures, S`evres, 2008), 120 p.

2. B.N. Taylor, C.E. Kuyatt, The new NIST policy on state-ments of uncertainty, CRTD, International forum on di- mensionaltolerancing and metrology, ASME 27, 7983(1993)

3. R.G. Wilhelm, R. Hocken, H. Schwenke, Task Specic Uncertainty in Coordinate Measurement, CIRP Ann. Manuf. Technol. 50, 553563 (2001)