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REJECTION REDUCTION

REJECTION REDUCTION. OLD METHOD Component Name : Bearing Housing Component weight : 20Kgs Number of Castings per Mold : 1nos. Total Good Casting wt : 20Kgs Total Pouring wt : 30.5kgs Yield : 65.5%. REJECTION DESCRIPTION

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REJECTION REDUCTION

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  1. REJECTION REDUCTION OLD METHOD Component Name : Bearing Housing Component weight : 20Kgs Number of Castings per Mold : 1nos. Total Good Casting wt : 20Kgs Total Pouring wt : 30.5kgs Yield : 65.5% REJECTION DESCRIPTION Component getting rejected at customer end after machining due to shrinkage problem

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

  3. Picture shows Hotspot inside the Casting & Feeder Hotspot specifies the isolated regions and solidification time Hotspot inside the casting

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

  5. REJECTION REDUCTION • Corrective Action • Process changed to Furan Fast Loop Line from High Pressure Molding line • Feeder position and neck size corrected. • Number of Castings per Mold increased to 2 from 1

  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 Hotspot inside the Casting & Feeder Hotspot specifies the isolated regions and solidification time

  9. Finding after implementation of this method Hotspot moved to feeder and there is no defect noticed inside the casting. Yield also increased by 7%

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