6 MONTH INTERNSHIP AT

MADE BY - ADITYA THOMBARE

SYMBIOSIS INSTITUTE OF TECHNOLOGY PRN- 1700121158

INSIGHT OF THE COMPANY KIRLOSKAR BROTHERS LTD, (KBL) incorporated in 1920 is a acknowledged

leader in fluid handling and largest manufacturer and exporter of pumps in India.

The company's product range includes a wide range of Centrifugal Pumps for Agriculture, Domestic, Industrial process , general applications , large vertical pumps , concrete volute pumps for Power Projects, Water Supply and Irrigation schemes ranging from Domestic Pumps of 0.375 Kw to concrete volute pumps of 4500Kw.

KBL’s Global Network includes Regional Offices in all the major cities in India and offices and representatives posted in various countries in Europe, Middle East and South East Asia.

Its products and services are exported to over 70 countries across five continents. On both the national and international fronts.

DEPARTMENTS WITHIN THE COMPANY

HRMC

PATTERN SHOP

FOUNDRY

MACHINE SHOPPUMP TESTING

PACKING

DISPATCH

DEPARTMENT DETAILS

CENTRAL PATTERN MANUFACTURING

CAD CAM

PROCESS DETAILS IT STARTS WITH THE DESIGN DEPARTMENT providing the drawing of the related pump

with all details , then the CAD engineer analyses and produces the pattern and necessary core for making a casting.

The Manufacturing of a pattern is also decided on the basis of how frequently they would be utilised-

Temporary- Thermacol pattern

Few castings- Wood

Large requirement – Aluminium

Besides even dies(Aluminium) are made for making highly finished castings.

These patterns after their use are stored in pattern store where they can be reproduced as in when the customer order is generated.

INSIGHT OF THE PATTERN PROCESS A casting is made from 2 basic things = Pattern + Core box

The cores are separated as per convenience for easy casting removal.

PROJECT DETAILSThe company assigned 3 projects which included :

Pattern Management System ( Material Management)

Angular Drilling machine stand (Jig to guide the drill in any angle)

Reverse Engineering of a impeller

Out of which :

Pattern Management System took about-- 3 months

Drilling machine stand took about -- 2 months

And reverse Engineering project – 1 month

All the 3 project had different impact providing knowledge of various works of Mechanical Engineering.

PATTERN MANAGEMENT SYSTEMNEED FOR MANAGEMENT-

Patterns and Core boxes form the basics of manufacturing a simple casting. They both are developed on the basis of the requirement or order placed by the consumer. Pattern along with the core box made is sent to the foundry for making a casting.

These patterns and core boxes need to be maintained with proper care so that they can be re-used when required again. If not maintained, they further have to be made again which is not at all cost efficient. Thus maintaining a pattern and its core box is very essential as it is a major asset to the company, which can cause a great deal of loss.

Further if not kept at the right place or in a right manner it becomes very difficult to search or find the necessary pattern when needed. This leads to panic or dependency of the company to a particular person or authority. To avoid all such problems, a proper systematic arrangement or a management is necessary which guides every related employee of the company to search the required equipment when in need. (Equipment= patter +core box)

SOLUTION PROVIDED

To avoid all above problems a project of pattern

management was adopted to minimize the effort

Initially layouts of the stores containing the patterns were

drawn to know the area well and to plan and utilize the

space efficiently

These storage areas were given particular names and rack

system was adopted to simplify the problem

LAYOUT OF THE EXISTING STORE

Besides the details of the racks were calculated including dimensions and giving names to all of them.

Also in order to create a database of the patterns and core boxes the equipments were counted manually along with the name, material, size, date of manufacturing of the pump.

On the basis of noted data an excel database of about 4000 pieces of both patterns and core boxes were found

With help of such database the patterns came to be sorted out on the basis of condition of it.

After all the data collection the used and unused patterns were separated and the unused were disposed to the scrap yard and all the frequently used ones were collected together.

It was decided to arrange them in the racks on the basis of their sizes and need.

Each of the top and bottom and their core boxes were arranged in such a way that all the work could be done by coming into one store.

The top were kept in one rack their other half i.e. its bottom was kept in the rack in front of the earlier rack and their core boxes were kept below the racks for their easy removal.

Besides color coding system was to be adopted to recognize particular equipment.

So on the basis of series decided the patterns were colored with specific colors along with their core boxes and a signboard indicating the color code was put up at the entrance of the pattern store.

Some of the images here describe the related work :

On the basis of color coding a layout containing the equipments was made to easily guide any related person within the company -

ANGULAR DRILLING MACHINE STANDREQIUREMENT :

The Pattern shop along with manufacturing of Patterns and Core Boxes also produces dies(Aluminium) for making Thermacol patterns used for producing high finish castings.

These dies are made of aluminium and have intricate parts which are machined on the VMC by using programming.

These dies need air passages for adding steam in the die to fuse the Thermacol balls by using a process called REPLICAST to generate a high finish casting.

These air passages were manually drilled earlier.

The parts of the dies have hydraulic shapes of the vane, casing etc. On which manual drilling caused a lot of problems like breaking of the drill ,change in the angle in which the drill has to be drilled and much more.

In order to overcome all these problems a concept of making an angular drilling machine stand was generated in the department which was to be fulfilled.

With the guidance of the Sir Dhananjay Sankpal (Ass.Manager) the concept was understood and the 3-D drawing of the concept was made initially.

A drawing of the 3-model is shown below-

By help of this 3-D model a 2-D model was generated and machining and other tolerances were added by the MED(Manufacturing Engineering Division) division

As the stand needed to be sturdy – steel was selected as the material to be used (WBC)

The material was searched through the scrap yard and the material was re-used from the scrap out of which 2 parts were casted out in the ACS foundry by making Thermacol pattern of each of them.

All the collected parts were then started to be machined by considering all the machining allowance and tolerances.

Following were the manufacturing processes used – Facing

Turning

Parting

Drilling

Milling

Key way slotting

Welding

Grinding

• After machining it was assembled together and a table having T-slot was found from scrap yard and the assembly was mounted on the table creating a fix position.

Later, on testing it was found that modification was necessary and thus use of linear bearings was done for the smooth movement of the sliding arm holding the hand drilling machine.

COSTING -

Approximate cost estimation of the project was done to calculate the investment done in manufacturing and show the savings.

This is the detailed costing of each part of the assembly :

REVERSE ENGINEERING A systematic methodology for analyzing the design of an

existing device or system, either as an approach to study the design or as a prerequisite for re-designs.

The process of duplicating an existing component, subassembly or product, without the aid of drawings, documentation, or computer model is known as reverse engineering.

Reverse engineering can be viewed as the process of analyzing a system to:

Identify the system's components and their interrelationships.

Create representations of the system in another form or a higher level of abstraction.

Create the physical representation of that system

Need of Reverse Engineering:

Some bad features of a product need to be design out.

To strengthen the good features of a product based on long-term usage of the product.

To analyze the good and bad features of the competitors product. To explore new avenues to improve product performance and features.

To gain competitive benchmarking methods to understand competitor's products and develop better products.

Reverse Engineering is done in 4 stages:

Stage 1: Evaluation and verification

Stage 2: Technical data generation

Stage 3; Design verification

Stage 4: Project implementation

DATA CAPTURE DATA SEGMENTATION 3D CAD MODEL

AREAS IN WHICH REVERSE ENGINEERING IS APPLICABLE:

Lost documentation: Reverse engineering often is done because the documentation of a particular device has been lost (or was never written), and the person who built it is no longer available. Integrated circuits often seem to have been designed on obsolete, proprietary systems, which means that the only way to incorporate the functionality into new technology is to reverse-engineer the existing chip and then re-design it.

Product analysis. To examine how a product works, what components it consists of, estimate costs, and identify potential patent infringement.

Digital update/correction. To update the digital version (e.g. CAD model) of an object to match an "as-built" condition.

Acquiring sensitive data by disassembling and analyzing the design of a system component [3]

Military or commercial espionage. Learning about an enemy's or competitor's latest research by stealing or capturing a prototype and dismantling it.

Creation of unlicensed/unapproved duplicates. Academic/learning purposes. Curiosity Competitive technical intelligence (understand what your competitor is actually doing

versus what they say they are doing) Learning: learn from others' mistakes. Do not make the same mistakes that others have

already made and subsequently corrected

STEPS IN REVERSE ENGINEERING

DATA ACQUISITION TECHNIQUES

THESE WERE THE METHODS FOLLOWED FOR VERIFICATION OF A PARTICULAR DESIGN

BESIDES THE PROJECTS GIVEN –THERE WERE SOME 5S AND KAIZEN INITIATIVES TAKEN ON THE SHOP FLOOR

KAI ZEN

“Kai” in Japanese means “Change” and “Zen” means

good. The literary meaning of Kaizen is

“change for good”

BEFORE/AFTER

BEFORE/AFTER

BEFORE/AFTER

THE END