4.

5 PROCESS FLOW CHART OF RIM MANUFACTURING Loading of coil on decoiler Tig welding Drain hole Stamping Knurling Form rolling Seam welding Profile rolling Auto cutting Butt welding Sizing machine

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Auto punching Loading of coil on de-coiler:Hero cycle used coils for the manufacturing of the rims. It has own plant that made steel coils named as CR Division Size of the coil for standard cycle rim: 76.20*0.850 mm Picture shows mounting of coil on de-coiler-:-

Tigwelding:In rim plant tig welding is used for making a joint of coils during one coil is finished.

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Accumulator:Fig. shows construction of accumulator. Accumulator is mainly a well. It is usage is that the worker can made a joint in coils without stopping the mill machine.

Drain hole:These are the small hole made in inner side of the rim to remove the water and other type of fluid during the different process.these holes are produced on strip in the zigzag way.

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Stamping:during this process stamp of hero cycle is made on rim. Manufacturing date, and size of the rim is stamp on the rim

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Knurling:In ranger cycle the knurling is made at the outer sides of the rim for making braking system more effective.

View on one side

view on other side

Form rolling:In form rolling, rollers of different shapes are used for rolling of the coil at its outer edges. Picture shows the process of form rolling.

Seam welding:Seam welding used for welding a coil after rolling of coil at the inner side of the rim.fig shows process of seam welding.

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Profile rolling:During the profile rolling roller of different shapes are used for giving the shape to the rim at the middle portion of the rim. Picture shows the process of profile rolling.

Auto cutting:78

During auto cutting rim of different sizes are cut automatically. In hero cycle larger rimes are made of following sizes:- 28*1.5 inch 26*1.5 inch 24*1.5 inch

Butt welding:It is used for making a butt joint to joint the two sides of the rim for making complete circular rim. Fig. shows butt welding machine.

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Sizing machine:-This machine is used to check the size of the rim. Fig shows sizing
machine. It works on pneumatics system means works on compressed air.

Auto punching:There is an auto punching machine for making a hole and valve hole at the periphery of the rim automatically. Fig shows auto punching machine.

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There are many other machines are used in rim plant. These machines play important role in a rim plant. Following are the machines. Re-seem welding Manual punching machine Cutting press Re-rolling machine

Take knowledge under the maintance department. Repairing of gear boxes used in form rolling and profile rolling. Assembling and disassembling of gear boxes. Electrode changing of seem welding in case of faulty electrode

Seeing all processes under supervisor that made for converting the steel coil into final rim Rim plant also containing electroplating of rim and polishing of rim

Project on reduction of tool consumption in mill of manufacturing by-cycle rim:

In rim plant, there are seven mills for manufacturing of rim of different shapes and sizes. During the manufacturing of rim, rim undergoes in seem welding operation as shown above in manufacturing processes of a rim. Seem welding is used to weld the inner sides of the steel coil after the form rolling processes. In seem welding the 350v of current is set for the effective welding of the rim. During the seem welding operation the electrode of the seem welding machine is sparked at the contacting surface of electrode and rim coil due to high voltage and the electrode get darked with black colour at its outer periphery due to this rim made defective. To remove this defect electrode is mounted with electrode sharping tool.Fig shows the mounting of tool with electrode

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Electrode

Tool

This tool is made of high speed steel. The high speed steel containing many elements other than iron. The chemical composition of HSS is Carbon0.65 to 0.80 percent Chromium Tungsten Vanadium 3.75 to 4.00 percent 17.25 to 18.75 percent 0.90 to 1.30 percent

And in very small proportions cobalt, molybdenum and aluminium and other elements that may be present in small quantities are manganese, silicon, nickel, copper, phosphorus and sulphur. I do our project with the guidance of Mr. Pardeep verma manager of rim production dept. On mill no. 9 and mill no. 10 of rim plant. The tool used in seem welding is shown in this fig.

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As shown in a fig. this single tool is used up to above lines after that there is no further usage of this tool. After that new tool is used for sharpening the electrode

Collection of past data regarding the consumption of tool: MONTH December January February CONSUMPTION OF TOOL/MONTH 11 9 10

The average consumption of tool per month is 10 HSS tool comes in industry as rectangular piece as shown below. After that it is designed in required shape as per the requirement. Grinding operations is done on rectangular piece of HSS tool, for giving required shape. Approximately one and half day of workers is consumed in giving the required shape to the tool used in one month.

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So about this study, I talked with Mr. Pardeep Verma and get decision for doing changes in design of the tool so that consumption of that tool is reduced.

Changes in design of Tool used in Seem welding operation:

There is a small change between the old design of the tool and the modified design of tool. In old design as shown in below fig there is a cutting portion of tool shank. That is the week part of that tool. The tool is used only above that portion. If that tool is again used it will break because of low strength.

Cutting portion

Modified design of the tool:

Fig shows the modified design of the tool. There is no week section of tool,the cutting portion in the shank of tool is eliminated. In operation or in mounting of the tool, there is no usage of that cutting portion.

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Result and Cost Benefit:

Tool consumption reduced from 10 tools/month to 5 tools/month. Grinding operation eliminated which resulted into saving of 1.5 man days/month. Cost saved : Cost of the one tool is = Rs.1891 Cost of the man power = Rs. 1000 Cost of the 5 tool is 1891*5 = 9455 Total cost saved: 9455+1000 = 10455 per month

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