NEW PRODUCT DEVELOPMENT

1. NEW PRODUCT DEVELOPMENT By V.Neville Gnanaraj

2. Magna Digitech is in the Business of Providing Engineering Service to the Mechanical Engineering Domain. • Incorporated in 2003 • Core competency in Mechanical Engineering Domain • 40 Man Years Experience • Magna Digitech can provide the following services • Mechanical Engineering • Legacy conversion to 2D drawings • Developing 3D models • Reverse Engineering • Finite Element Analysis • Jigs & Fixture Design • Software Available • ProE Wildfire 5 • Solidworks 2013 • Unigraphics NX • AutoDesk Products • SolidEdge V18 • Magmasoft 5.2 • Foundry • Casting design • Tool Model • Conversion from Fabrication to Casting • Casting Simulation

3. New Product Development - Expectations • Right First Time and Every Time • On Time Product Development • Producing The Casting at Right Cost How to achieve this??

4. New Product Development - Process Tool Design Design review and Final Output Method Design Tool Manufacturing and Review Trial Process Process Parameters Fixing Validation of Trial by User Departments Check Points to be Validated before Trial Detailed Action Plan Handing Over to Production

5. New Product Development - Plan

6. Case Study - 1 • Component Name: Lever Cover (Ductile Iron) • Brief Description and Technical Challenges. • Casting weight 2.6Kgs • Wall Thickness 6mm +/- 0.5 • X-ray – Level 2

7. L0 Results

8. Hotspot Results Bottom Top

9. Final Simulation Results

10. Filling Results

11. Solidification Results

12. Hotspot Results

13. Porosity Results

14. Actual Results Samples Sent and released for production. Unfortunately we are not able to complete the schedule due to high in-house rejection..

15. Reason for Rejection • Wall Thickness Variation • Initially we have cleared the design for tool manufacturing considering • Method validated through simulation • Proper core print provided at center of to avoid core tilt and further bottom of chill will rest on mold.

16. Analysis for Rejection • Cavity 2 & 4 has less wall thickness at top and cavity 1 & 3 has less wall thickness in bottom. 1 2 4 3

17. Cause for Rejection • Metal flow direction which triggers the lift of core 1 2 4 3 • But we have anticipated the same problem during our design stage and assumed this will be taken care by seating of chill bottom to mold.

18. Real Cause for Rejection • Variation in chill ht. • All the chills ensured - it should not exceed its maximum height and at the same time no record for minimum size. • Rejection due to wall thickness variation eliminated after removing chills not meeting the spec.

19. Case Study - 2 • Component Name: Central Housing ( Grey Iron ) • Brief Description and Technical Challenges. • Casting weight 1.3Kgs • No defect after machining

20. Shell Core • Core weight 0.62kgs

21. L0 Results

22. Hotspot Results

23. Final Simulation Results

24. Filling Results

25. Solidification Results

26. Actual Results Major rejection is due to blow hole..

27. Analysis and Action • Blow hole defect due to gas generation in core • Various type of resin coated sand tried • Core gas vents provided in parting line. • Result • There was an improvement. • But Not to the expected level.

28. Real Cause for Blow hole • The resin coated silica sand is not suitable for component like this. • Changed the process – Core with resin coated quartz sand. • Drill holes provided in core print to the possible extend. • Rejection due to Blow hole eliminated by changing core process

29. Lesson Learnt. • Tools like simulation software can help to achieve result. ( say 90%) • Simulation tools can describe the system behavior under given conditions. • Validate the defined process parameters before using them. • Select appropriate process to meet the target.

30. T H A N K Y O U