PRODUCTIVITY IMPROVEMENT OF SHAKTI PT LABYRINTH ...

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana sangama, Belgavi, Karnataka – 590 014

Project Report

on

“PRODUCTIVITY IMPROVEMENT OF SHAKTI POWER TURBINE

LABYRINTH CAGE”

Submitted in partial fulfillment of the requirement for the award of degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SUBMITTED BY

Under the guidance of

Prof. SRINATH M K

Asst. Professor,

Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

NEW HORIZON COLLEGE OF ENGINEERING BANGALORE-560 103

2017-18

B MOHAMMED ALTAF 1NH14ME030

ABHISHEK 1NH14ME001

ASIF ALI U BOODIHAL 1NH14ME027

MRIGANKA DEKA 1NH14ME173

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

It is certified that the technical seminar entitled “PRODUCTIVITY

IMPROVEMENT OF SHAKTI POWER TURBINE LABYRINTH CAGE” is

work carried out by B MOHAMMED ALTAF, ABHISHEK, ASIF ALI U

BOODIHAL, MRIGANKA DEKA are bonafide students of New Horizon College

of Engineering, Bangalore in partial fulfillment for the award of degree of Bachelor

of Engineering in Mechanical Engineering of the Visvesvaraya Technological

University, Belgaum during the year 2017-18. It is further certified that all

corrections/suggestions indicated for internal assessment has been incorporated in the

report deposited in the departmental library. The Project Report has been approved as

it satisfies the academic requirements in respect of Project Work prescribed for the

said degree.

Signature of the guide Signature of the HOD Signature of the Principal Prof. Srinath M K Dr. M S GANESHA PRASAD Dr. Manjunatha Asst. Professor, Dean-Student Affairs & HOD-ME, Principal

Dept. of Mechanical Engineering. Dept. of Mechanical Engineering. NHCE

Name(s) of the student: University Seat Number(s):

BB MMOOHHAAMMMMEEDD AALLTTAAFF 11NNHH1144MMEE003300

AABBHHIISSHHEEKK 11NNHH1144MMEE000011

AASSIIFF AALLII UU BBOOOODDIIHHAALL 11NNHH1144MMEE002277

MMRRIIGGAANNKKAA DDEEKKAA 11NNHH1144MMEE117733

External Examiner(s) Signature with Date

1.

2.

ABSTRACT

“Productivity optimization through re-engineering thefixtures used for labyrinth cage

of Shakti engine”, used inadvanced light helicopter.

The objective is to improve the productivity of SHAKTI PT LABYRINTH CAGE.

Milestone chart was drawn for monitoring the activities. Structured brain storming

sessions were conducted, for data collection and analysis of the problem. The problem

was categorized under 4M’s (Man, Machine, Material and Method). Each and every

cause was discussed in depth for arriving to a root cause.

High setup and cycle time of CNC turning operation was due to use of soft jaws and

carrying out the operation. This traditional system requires machining of soft jaws

every time they are loaded, thus increasing the setup time.

Manufacturing department members with our batch discussed all the solutions and

solved this problem by developing changes in the fixture and cutting parameters to

carry out the above laid operations. There by eliminating the setup time for operation

and rejection rate is completely eliminated, also the cycle time was reduced by around

4 hours.

ACKNOWLEDGEMENT

The satisfaction that accompanies the successful completion of any work would be

incomplete without the mention of the people who made it possible and whose

constant encouragement and guidance has been a source of inspiration through the

course of completion of this technical seminar.

We express our sincere gratitude to Sri MOHAN MANGHNANI, Chairman, and

the management of New Horizon College of Engineering for providing this

endower.

We wish to express our sincere gratitude and thanks to Dr. M.S GANESHA

PRASAD, Head of Mechanical Department, New Horizon College of

Engineering, Bengaluru, as

wellasDr.MANJUNATHA,Principal,NewHorizonCollegeofEngineering,Bengalu

ru for providing facilities, friendly atmosphere and encouragement to complete the

project worksuccessfully.

WesincerelythankourguideMr.SRINATH M K,Asst.Professor,Department of

Mechanical Engineering, New Horizon College of Engineering, Bengaluru, for his

immense guidance, invaluable inspiration, words of advice and unstinted support

throughout this projectwork.

We respect and owe our deep gratitude to our external project guide Mr. C

SURYAKUMAR,SeniorManager,CNCdepartment,Engine division,

forprovidingus an opportunity to do the project work in HINDUSTAN

AERONAUTICS LIMITED. Although he had busy schedule managing the PSU

affairs, he took keen interest in our project and guided us all along till the

completion of our project work by providing all the necessary information and

support which made us complete the project duly. We are extremely thankful to

him for providing guidance and goodsupport.

We are thankful to our parents and friends for their blessings, moral support,

encouragement that has enabled me to complete this project work successfully.

INDEX

CERTIFICATE I

ACKNOWLEDGEMENT II

ABSTRACT III

CONTENTS IV

CONTENTS

CHAPTER1:INTRODUCTION 1

1.1 : CNC MACHININGPROCESS 2

1.2 : APPLICATIOMS OF CNC 4

1.3 : ADVANTAGES AND LIMITATIONS 5

1.4 : SHAKTI ENGINE 5

1.5 : TURBOSHAFTENGINE 6

1.6 : MODULES INVOLVED IN BUILT

OFSHAKTIENGINE 8

1.7 : POWER TURBINE 8

CHAPTER 2: WORKSHOP AND THE MACHINES 10

2.1: CTX GAMMA 1250 TURNMILLCENTRE 10

CHAPTER 3: LABYRINTHSEALS 13

3.1: COMPONENTS OF LABYRINTHCAGE 15

CHAPTER 4: LITERATURESURVEY 19

CHAPTER5:FIXTURES 29

5.1: GENERAL CONSIDERATIONS OFFIXTUREDESIGN 30

CHAPTER 6: MATERIALSELECTION 33

CHAPTER7: METHODOLOGY 35

CHAPTER 8: BASIC PROCESSES IN MAKINGLABYRINTHCAGE 36

CHAPTER9: CONCLUSION 49

REFERN

CES

REFERENCES

1. Thermal fatigue resistance of welded joints in stainless steel high temperature exhaust

application by Laurent & Pierie-olivier.

2. Material science and metallurgy by Phaneesh.

3. Material science and metallurgy by O P Khanna.

4. Mechanical measurements and metallurgy by Phaneesh.

5. Fundamentals of geometric dimensioning and tolerancing by Alex Krulikowski.

6. Fundamentals of geometric dimensioning and tolerancing by Gene Cogorno.

7. Thermal stresses and low cycle fatigue by Mansos S S.

8. Design of jigs fixtures and press tools by K Venkataraman.

PRODUCTIVITY IMPROVEMENT OF SHAKTI PT LABYRINTH CAGE

DEPT OF ME, NHCE Page 1

CHAPTER 1

INTRODUCTION

Productivity is a measure of output (produced from each hour of work) per unit of

input, from a certain production process.

Productivity Improvement involves analyzing the current operations processes and

determining specific, high impact areas of opportunity. Productivity improvement

strategies can then be put in place to increase efficiency as well as production output.

Benefits from productivity improvement include a decrease in overall cost combined

with an increase in revenue.

The project was done in the esteemed organization Hindustan Aeronautics Limited

(HAL).

The beginning of Hindustan Aeronautics

Limited can be traced back to the year 1940

when an eminent and foresighted

industrialist, Late Mr. Walchand Hirachand

setup the company called “HINDUSTAN

AERONAUTICS LIMITED” in association

with the Mysore Government. The

company was officially registered on

December 23, 1941 as a private company.

The collaboration was established with the

Intercontinental Aircraft Company, for the

maintenance of such aircraft as the Harlow

Trainer Curtis fighter and the Vulture

Attack Bomber.

After the flight of the Harlow trainer in 1941, HAL’s pride got a further boost due to

the successful flight of India’s first indigenously effort to ten scatter gliders designed

and built under Dr. V.M. Ghatage from the engineering department. The Second World

War saw the aircraft manufacturing efforts being abandoned in favor of repair and

overhaul services and HAL became the principle overall base for the South-East

Command of the Allied Forces. In 1945, Government of India took over the

management and activities which increased manifold after India attained freedom.



After Independence, Hindustan Aeronautics Limited restructured itself for the

design, development and manufacture of a variety of aircrafts. During the 59 year

Independence era, HAL has excelled in the research and development of

indigenously designed trainers, helicopters like CHEETAH, CHETAK,

ADVANCED LIGHT HELICOPTERS(ALH) and multirole fighters such as MIG’S,

JAGUAR, MIRAGE, DORNIER, PUSHPAK, KIRAN and LIGHT COMBAT

AIRCRAFT(LCA).

The company has also expanded its domain into the Aerospace field.

Today HAL is one of the largest aerospace complexes in Asia and the fourth largest

aircraft manufacturer in the world. It plays a crucial role in the Indian ambition for

broad based industrialization with growth emphasis, to become not only self reliable

in defense production but also to become an international partner in civil aircraft

manufacture and maintenance. HAL has 4 complexes namely:

RESEARCH AND DEVELOPMENT COMPLEX

BANGALORE COMPLEX

ACCESSORY COMPLEX

MIG COMPLEX

1.1 COMPUTER NUMERICAL CONTROL (CNC) MACHINING

PROCESS CNC machining is a manufacturing process in which pre-programmed computer

software dictates the movement of factory tools and machinery. The process can be

used to control a range of complex machinery, from grinders and lathes to mills and

routers. With CNC machining, three-dimensional cutting tasks can be accomplished

in a single set of prompts.

Short for “computer numerical control,” the CNC process runs in contrast to — and

thereby supersedes — the limitations of manual control, where live operators are

needed to prompt and guide the commands of machining tools via levers, buttons and

wheels. To the onlooker, a CNC system might resemble a regular set of computer



components, but the software programs and consoles employed in CNC machining

distinguish it from all other forms of computation.

When a CNC system is activated, the desired cuts are programmed into the software

and dictated to corresponding tools and machinery, which carry out the dimensional

tasks as specified, much like a robot.

In CNC programming, the code generator within the numerical system will often

assume mechanisms are flawless, despite the possibility of errors, which is greater

whenever a machine is directed to cut in more than one direction simultaneously.

The placement of a tool in a numerical control system is outlined by a series of

inputs known as the part program.



With a numerical control machine, programs are inputted via punch cards. By

contrast, the programs for CNC machines are fed to computers though small

keyboards. CNC programming is retained in a computer’s memory. The code itself is

written and edited by programmers. Therefore, CNC systems offer far more

expansive computational capacity. Best of all, CNC systems are by no means static,

since newer prompts can be added to pre-existing programs through revised code.

In CNC, machines are operated via numerical control, wherein a software program is

designated to control an object. The language behind CNC machining is alternately

referred to as G-code, and it’s written to control the various behaviors of a

corresponding machine, such as the speed, feed rate and coordination.

Basically, CNC machining makes it possible to pre-program the speed and position

of machine tool functions and run them via software in repetitive, predictable cycles,

all with little involvement from human operators. Due to these capabilities, the

process has been adopted across all corners of the manufacturing sector and is

especially vital in the areas of metal and plastic production.

For starters, a 2D or 3D CAD drawing is conceived, which is then translated to

computer code for the CNC system to execute. After the program is inputted, the

operator gives it a trial run to ensure no mistakes are present in the coding.

1.2 APPLICATIONS OF CNC

The applications of CNC include both for machine tool as well as non-machine tool

areas. In the machine tool category, CNC is widely used for lathe, drill press, milling

machine, grinding unit, laser, sheet-metal press working machine, tube bending

machine etc. Highly automated machine tools such as turning center and machining

center which change the cutting tools automatically under CNC control have been

developed. In the non-machine tool category, CNC applications include welding

machines (arc and resistance), coordinate measuring machine, electronic assembly,

tape laying and filament winding machines for composites etc.



1.3 ADVANTAGES AND LIMITATIONS

The benefits of CNC are:

(1) High accuracy in manufacturing

(2) Short production time

(3) Greater manufacturing flexibility

(4) Simpler fixtures

(5) Contour machining (2 to 5 –axis machining)

(6) Reduced human error.

The drawbacks include:

(1) High cost.

(2) Maintenance

(3) Requirement of skilled part programmer.

1.4 SHAKTI ENGINE

The Turbomeca Ardiden is a family of turbo shaft engines featuring simple, modular

and compact design. They are built around a gas generator with two centrifugal

compressor stages, coupled to a single-stage high-pressure turbine. The power

turbine comprises two stages. Ardiden engines satisfy the most demanding mission

requirements, while retaining full performance under high altitude and hot

temperature conditions.

Specification of Shakti engine

Oil consumption =0.2 ltr/hr

Compression ratio= 12.7:1

Air mass flow=3.75kg/sec

Power turbine speed = 20889 rpm

Gas generator speed = 39598rpm

Output shaft speed = 6000rpm

Height= 707mm

Width=571mm Length= 1279m

Weight=205 Kg

Max take off power= 1032 kW

Figure 1.1 SHAKTI ENGINE



The Shakti, also known as Ardiden 1H1, is a turbo shaft engine jointly developed by

Turbomeca (France) and Hindustan Aeronautics Limited (HAL) based on the Ardiden

turbo shaft to power weaponized variants of the Dhruv Advanced Light Helicopter

(ALH). It made its maiden flight powering the Dhruv helicopter on August 16, 2007.

The first Ardiden 1H1 re-engineered Dhruv helicopter took to the skies on January 12,

2009.

The Shakti features three modules for easy maintenance: a reduction / accessory

gearbox module, a gas generator module and a power turbine module. The Time

between Overhaul (TBO) ranges from 3,000 to 6,000 hours. The Shakti engine

delivers 30 percent more power than TM333-2B2 power plant, which also powers

the Dhruv, and features 19 percent of components developed in India. The Shakti

may be the prime candidate for powering the future Light Combat Helicopter (LCH)

also being developed by HAL.

1.5 TURBOSHAFT ENGINE

Shakti Engine is a turbo shaft engine as mentioned above. A brief view about Turbo

shaft engine is given below.

A turbo shaft engine is a variant of a jet engine that has been optimized to produce

shaft power to drive machinery instead of producing thrust. Turbo shaft engines are

most commonly used in applications that require a small, but powerful, light

weight engine, inclusive of helicopters and auxiliary power units.

A turbo shaft engine uses the same principles as a turbojet to produce energy, that is,

it incorporates a compressor, combustor and turbine within the gas generator of the

engine. The primary difference between the turbo shaft and the turbojet is that an

additional power section, consisting of turbines and an output shaft, has been

incorporated into the design. In most cases, the power turbine is not mechanically

linked to the gas generator. This design, which is referred to as a "free power

turbine", allows the speed of the power turbine to be optimized for the machinery

that it will energize without the need for an additional reduction gearbox within the

engine. The power turbine extracts almost all of the energy from the exhaust stream

and transmits it via the output shaft to the machinery it is intended to drive.

A turbo shaft engine is very similar to a turboprop and many engines are available in



both variants. The principal difference between the two is that the turboprop version

must be designed to support the loads of the attached propeller whereas a turbo shaft

engine need not be as robust as itnormally drives a transmission which is structurally

supported by the vehicle and not by the engine itself.



1.6 MODULES INVOLVED IN BUILT OF SHAKTI

ENGINE

There are three modules in the build namely:

Reduction Gearbox.

Gas Generator.

Power Turbine.

Figure 1.2: different modules of Shakti engine

1.7 POWER TURBINE

Turbine engines are more powerful and are used in a wide variety of helicopters.

They produce a tremendous amount of power for their size but are generally more

expensive to operate. The turbine engine used in helicopters operates differently

from those used in airplane applications. In most applications, the exhaust

outlets simply release expended gases and do not contribute to the forward motion of

the helicopter. Approximately 75 percent of the incoming airflow is used to cool the

engine.

Power turbine extracts energy from the gas to drive the main power drive. It is

located at the rear of the engine. The power turbine assembly forms the module 3.



Figure 1.3: power turbine module



CHAPTER 2

WORKSHOP AND THE MACHINES

The workshop where the project was conducted is the SHAKTI CNC WORKSHOP.

The machines that can be found in the workshop are as follows

1. CTX Gamma 1250 Turn Mill Centre-works on Siemens 840DSL and is

capable of machining in 5 axis. It can work on a component weighing 1000kgs

having dimensions 600mm diameter and length of 1250mm and can accommodate

12 tools.

2. Hardinge Elite II- works on FANUC and is capable of machining in 2 axes the

tool holder can accommodate 12 tools and is a turn mill centre.

3. HMT SBCNC-60/1250– Works on Siemens 840DSL and is a two axis machine

centre is a CNC Disk Lathe.

4. DMC 100 U DUOBLOCK– Works on Siemens and is a two pallet machine. It

is a five axis machine. The machine has two pallets to reduce the setup time.

5. KEHREN CURVIC GRINDING MACHINE- It works on Siemens and is

a three axis machine. It has tracking teeth and is imported from Germany.

6. DMU MONOBLOCK SINGLE PALLET- It is similar to machine no.4 on

this list but the difference is that it has a single pallet.

2.1 CTX GAMMA 1250 TURN MILL CENTRE

The machine or the workstation where the major parts of the project has been

conducted is the CTX GAMMA 1250 TURN MILL CENTRE.

The CTX GAMMA 1250 is a Turning and Milling machine, which means both

turning operations and milling operations can be conducted on the same work

stations. The CTX GAMMA has a tool capacity of 12 at the same time. The CTX

gamma 1250 TC handles work pieces up to φ630 mm × 1,300 mm. The model offers

the linear specification equipped with the linear drive that achieves an acceleration of

1G and a rapid traverse rate of 60 m/min.



Figure 2.1: CTX

Gamma turn mill center Few specifications are

mentioned below:

Capacity 12 tools.

Max. dia of work piece (X) 600 mm

Max. length of work piece(Z) 1250 mm

Max. spindle speed

(Turn Mill Spindle) 2000 rpm

CONTROL AND SOFTWARE ALTERNATIVES

CELOS

SIEMENS

STC 20 SLANT BED TURNING CENTRE

STC 20 SLANT BED TURNING CENTRE is a turning centre where bar stocking or

bar slicing and various other turning operations are conducted.

The STC 20 has been designed for high productivity and accuracy, with high

traverse rates and reduced non-cutting times.

Figure 2.2: STC 20 machining center



Few specifications are mentioned below:

Swing over bed 420 mm

Maximum turning dia. 250 mm

Maximum turning length 600 mm

Chuck dia. 250 mm

Bar passage/Spindle bore 53 mm

Spindle power (100%) 7.5 kW

Speed range 100-4000rpm

CONTROL AND SOFTWARE ALTERNATIVES

FANUC

SIEMENS



CHAPTER 3

LABYRINTH SEALS

A labyrinth seal is a type of mechanical seal that provides a tortuous path to help

prevent leakage. An example of such a seal is sometimes found within an axle's

bearing to help prevent the leakage of the oil lubricating the bearing.

A labyrinth seal may be composed of many grooves that press tightly inside another

axle, or inside a hole, so that the fluid has to pass through a long and difficult path to

escape. Sometimes screw threads exist on the outer and inner portion. These

interlock, to produce the long characteristic path which slows leakage. For labyrinth

seals on a rotating shaft, a very small clearance must exist between the tips of the

labyrinth threads and the running surface. The "teeth" of the labyrinth seal may be on

the rotating shaft or on the stator, or both, in an interlocking configuration.

Labyrinth seals on rotating shafts provide non-contact sealing action by controlling

the passage of fluid through a variety of chambers by centrifugal motion, as well as

by the formation of controlled fluid vortices. At higher speeds, centrifugal motion

forces the liquid towards the outside and therefore away from any passages.

Similarly, if the labyrinth chambers are correctly designed, any liquid that has

escaped the main chamber becomes entrapped in a labyrinth chamber, where it is

forced into a vortex-like motion. This acts to prevent its escape, and also acts to repel

any other fluid. Because these labyrinth seals are non-contact, they do not wear out.

Many gas turbine engines, having high rotational speeds, use labyrinth seals due to

their lack of friction and long life. Because liquid-filled labyrinth seals still generate

heat due to the viscosity of the seal oil, and because seal oil can contaminate the

process fluids, modern high-performance gas turbines use dry gas seals which use

spring-loaded rings with an inert gas in between the faces of the rings to provide the

seal. This creates even lower friction and provides a liquid-free seal.

A labyrinth seal is placed inside a cage which is known as labyrinth cage.



FIGURE 3.1: Labyrinth cage



3.1 COMPONENTS OF LABYRINTH CAGE

1) Cage body

2) Flange

3) Deflector

4) Plasma coating

5) Carbide coating

Cage body: It deflects all the gases coming from the compressor and turbine to

the exhaust vent, away from shaft.

Flange: A flange is an external or internal ridge, or rim (lip), for strength

Deflector: Purge grease through shaft seals or through a 15 mm hole (relief port)

drilled in the housing. The hole must be on the side of the bearing opposite from the

grease nipple, at the bottom of the bearing housing when in service and between the

bearing and seal.

Plasma coating:

Plasma-sprayed coatings are heated powders applied on the shaft surface at a high

temperature (3000 "F) and high speed, resulting in high adherence to the shaft. The

shaft surface hardness will be equal to the hardness of the coating being applied.

After the coating is applied, the shaft must be machined to the desired surface finish.

Because thematerials being applied are very hard and the surface finish is very rough

after application, it is necessary to grind and have the shaft to the required surface

finish.

The coating process also leaves a porous surface, which can be sealed or coated with

a lubricant. The pores can be filled with a phenolic sealer or graphite-molybdenum

disulfide dry lubricant toprotect the substrate from harmful media.

Properties of Plasma-Sprayed Coated Surfaces

Plasma-sprayed coatings provide high hardness, high abrasion resistance, excellent



material uniformity, low abrasion to the seal, and good corrosion resistance when

pores are effectively sealed.

High Hardness

The hardness of a plasma-sprayed surface is determined by the coating being used. A

hardness of1300 HV (approximately 74 Rockwell C) can be obtained with chromium

oxide coatings. Lower hardness is obtained with aluminum oxide and tungsten

carbide coatings.

High Abrasion Resistance

Maxma-sprayed shafts attain excellent abrasion resistance, which makes the

materials ideal for use in abrasive environments such as steam, water, abrasive

materials, non-lubricated areas, and in high- speed or high pressure rotary

reciprocating service.

Uniformity

Plasma-sprayed coating uses metco(top coat) and amory(Bond coat). When applied

correctly, the plasma-sprayed coating has excellent matrix uniformity, as illustrated

in figure. This uniformity results in greater seal performance.

Low Abrasion to the Seal

The coatings are generally modular with rough edges, minimizing abrasion.

Corrosion Resistance

Plasma-sprayed coatings have a certain degree of porosity; however, such porosity

can easily be sealed so that plasma-sprayed shafts may be used in many aggressive

environments. After coating, a liquid phenolic sealer is applied to enhance corrosion



resistance. The sealer must be compatible with the fluid media to be effective.

Thickness of Coating

The coating thickness will depend on the application, but will vary from 0.0005 to

0.0030 in(from 0.127 to 0.762 mm).



HVOF Tungsten Carbide Coating

Tungsten carbide is chemical carbide containing equal parts of tungsten and carbon

atoms. It is approximately twice as strong as steel with double the density and is double

the density of steel. Tungsten Carbide’s hardness level is comparable with corundum

and can only be polished and finished with abrasives of superior hardness such as cubic

boron nitride and diamond powder, wheels, and compounds.

In its basic form, tungsten carbide is a fine gray powder, but it can be pressed and

formed into shapes for use in industrial machinery, cutting tools, abrasives, armor-

piercing rounds, other tools and instruments.

Why tungsten carbide?

It offers excellent wear for extreme conditions

It provides good surface for extremely hard coating materials

It provides rigid and dense substrate

It offers a greater degree of flexibility when needed (i.e., in applications

involving shaft flexibility)

Figure 3.3 : Tungsten carbide coating operation



CHAPTER 4

LITERATURE SURVEY

THERMAL FATIGUE RESISTANCE OF WELDED JOINTS

IN STAINLESS STEEL HIGH TEMPERATUREEXHAUST

APPLICATIONS

Weld seams often constitute critical points in the thermo-mechanical fatigue design

of a stainless steel automotive exhaust manifold. Therefore, a thermal fatigue test on

V-shaped specimens was developed by ArcelorMittalIsbergues Research Centre to

simulate the thermo-mechanical loading of such a part. Two ferritic base metals

dedicated to high temperature applications, together with various filler materials

(both austenitic and ferritic grades) commonly used in the exhaust market were

tested with a 250-950°C thermal cycle. The results were compared in terms of

lifetime, cracking mechanisms and micro-structural evolution in order to point out

the best base/filler metal combinations. For austenitic weld metals, the higher

thermal expansion coefficient than ferrite weld metals (50% higher) led to a more

pronounced oxidation and a higher level of stresses generated at the interface

between melted zone and base metal. Consequently, the cracks were localized to this

interface for austenitic filler material while they appeared in the base metal and out

of the heat affected zone for ferritic filler material.

The use of stainless steel in automotive exhaust parts has been growing for the past

decades, especially in very high-temperature conditions for parts such as

manifolds.(1,2) In comparison to cast iron, stainless steel fabricated solutions enable

both a weight reduction and a higher temperature resistance.(2,3) More and more

severe emission standards will lead the car manufacturers to consider higher exhaust

gas temperature to improve catalytic conversion efficiency but with equivalent or

stronger requirements on the part lifetime. New ferritic stainless steels have been

developed for that purpose(4,5) but given that stainless steel manifolds are welded

assemblies, the resistance to thermal fatigue of welds is of great interest for exhaust

manufacturers. In this framework, the present study aimed at describing the thermal

fatigue resistance of MIG/MAG and Laser butt welds on ferritic stainless steels

sheets.



® VDM Alloy 625

Nicrofer 6020 hMo

VDM® Alloy 625 is a nickel-chromium-molybdenum-niobium alloy with

excellent resistance to a variety of corrosive media. In the soft annealed

condition (grade 1; annealed at 950 to 1,050 °C (1,742 to 1,922 °F)), the alloy is

used for wet corrosion applications and is approved by TÜV for pressure vessels

in a temperature range from -196 to 450 °C (- 320 to 842

°F). For high temperature applications above 600 °C (1,112 °F), the solution

annealed variant (grade 2; annealed at 1,080 to 1,160 °C (1,976 to 2,120 °F)) is

generally used. The strength of VDM® Alloy 625 can be enhanced by heat

treatment.

VDM® Alloy 625 is also approved by ASME in both the grade 1 and grade 2

conditions for sections I, III, VIII and XII at temperatures defined in ASME

Section IID (temperature limits vary by construction code).VDM® Alloy 625 in

the soft annealed condition (grade 1) is characterized by:

Exceptional resistance to pitting, crevice corrosion, erosion and inter granular

corrosion

Immunity to chloride-induced stress corrosion cracking

Good resistance to mineral acids such as nitric, phosphoric, sulfuric and

hydrochloric acid

Good resistance to alkalis and organic acids

Good mechanical properties

VDM® Alloy 625 in the solution annealed condition (grade 2) is characterized by:

Excellent creep strength above about 600 °C (1,112 °F)

Good resistance to many types of hot gas corrosion, particularly chlorination

Designations

Mechanical properties

TEMPERATURE YIELD STRENGTH(MPa) TENSILE STRENGTH(MPa)

850 200 350

900 190 250

1000 100 120

Standard Material designation

EN 2.4856 - NiCr22Mo9Nb

ISO NC22DNb

UNS N06625

AFNOR NC22DNB



Microstructure properties

VDM® Alloy 625 has a cubic face centered lattice.

Corrosion resistance

Optimum corrosion resistance can only be obtained if the material is in the

correct metallurgical condition and possesses a clean structure. Under these

circumstances

In the soft annealed condition VDM® Alloy 625 (grade 1) has excellent corrosion

resistance to a variety of corrosive media:

Excellent resistance to pitting and crevice corrosion in chloride-containing

media

Virtual immunity to chloride-induced stress corrosion cracking

High resistance to corrosion attack by mineral acids such as nitric,

phosphoric, sulfuric, and hydrochloric acid; as well as by concentrated

alkalis and organic acids, both under oxidizing as reducing conditions

Very good resistance in seawater and brackish water, even at elevated

temperatures

High resistance to intergranular corrosion after welding and heat treatment

High resistance to erosion corrosion

In the solution annealed variant VDM® Alloy 625 (grade 2) is highly resistant to

many corrosive gas atmospheres:

Good resistance to carburizing and scaling under static and cyclic conditions

Resistance to nitriding

Good resistance to gases containing halogens, and hydrogen chloride

Applications

The soft annealed version of VDM® Alloy 625 (grade 1) is used in the oil and gas

industry, the chemical process industry, marine engineering and environmental

engineering. Typical applications include:

Equipment for the production of super phosphoric acid

Plants for the treatment of radioactive waste

Production pipe systems and linings of risers in oil production

Offshore industry and seawater exposed equipment

Sea water piping in ship building

Stress corrosion cracking resistant compensators and Furnace linings



The solution annealed variant of VDM® Alloy 625 (grade 2) is used for high temperature

applications up to 1,000 °C (1,832 °F), acc. to ASME Code for Pressure Vessels. Typical

applications include:

Flaring systems in refineries and offshore platforms

Recuperators and compensators for hot exhaust gases

VDM® FM 625 is used as a matching filler metal for corrosion-resistant coatings of less

resistant steels (overlay welding). Typical applications include:

Components in the oil and gas extraction

Super heater tubes in waste incineration plants

Fabrication and heat treatment

VDM® Alloy 625 can readily be hot- and cold-worked and machined. However,

machines are required for any operation that meets the high mechanical properties.

Heating

Work pieces must be clean and free of any contaminants before and during heat

treatment. Sulfur, phosphorus, lead and other low-melting-point metals can lead to

damages when heat treating VDM® Alloy 625. Sources of such contaminants include

marking and temperature-indicating paints and crayons, lubricating grease and fluids,

and fuels. Fuels should contain as little sulfur as possible.

Natural gas should contain less than 0.1 wt.-% of sulfur. Heating oil with a sulfur

content of maximum 0.5 wt.-% is also suitable. Electric furnaces are to be preferred

due to precise temperature control and freedom from contamination due to fuel. The

furnace atmosphere should be set between neutral and slightly oxidizing, and should

not change between oxidizing and reducing. Direct flame impingement needs to be

avoided.

Hot working

VDM® Alloy 625 may be hot worked in the temperature range 1,150 to 900 °C (2,100

to 1,650 °F) with subsequent rapid cooling down in water or by using air. The work

pieces should be placed in the furnace heated to hot working temperature in order to

heat up. Once the hot working temperature has been reached again, a retention time of

60 minutes for each 100 mm (4 in) of work piece thickness is recommended.

Afterwards, work pieces should be removed immediately and formed during the stated

temperature window. If the material temperature falls to 950 °C (1,742 °F), the work-

piece must be reheated.



Heat treatment after hot working is recommended in order to achieve optimum

microstructure and corrosion resistance.

Cold working

Cold working should be carried out on annealed material. VDM® Alloy 625

has a higher work hardening rate than austenitic stainless steels. This must be

taken into account during design and selection of forming tools and equipment

and during the planning of the forming processes.

Intermediate annealing may be necessary at high degrees of cold working

deformation. After cold working with more than 15 % of deformation the

material should be soft annealed (grade 1) or solution annealed (grade 2).

Heat treatment

VDM® Alloy 625 is used in applications where the operating temperatures are below

600 °C (1,112

°F) in the soft annealed condition (grade 1). The soft annealing is carried out at

temperatures of 950 to 1,050 °C (1,742 to 1,922 °F); a temperature of 980 °C

(1,796 °F) is preferred.

For applications above 600 °C (1,112 °F), the solution annealed variant of VDM®

Alloy 625 (grade 2), which provides optimized creep strength, is used. The solution

heat treatment should be carried out in the temperature range between

1,080 °C and 1,160° C (1,976 and 2,120 °F), preferably at 1,120 °C (2,048 °F).

Water quenching should be carried out rapidly to achieve optimum corrosion

characteristics. Work pieces of less than 3 mm (0.12 in) thickness can be cooled

down using air nozzles. The work piece has to be put into the pre-heated furnace.

The furnace should be heated up to the maximum annealing temperature.

Descaling and pickling

Oxides of VDM® Alloy 625 and discoloration adjacent to welds are more adherent

than on stainless steels. Grinding with very fine abrasive belts or discs is

recommended. Care should be taken to prevent tarnishing. Before pickling in a

nitric/hydrofluoric acid mixture, the surface oxide layer must be broken up by

abrasive blasting or grinding or by pre- treatment in a fused salt bath. Particular

attention should be paid to the pickling time.



Machining

VDM® Alloy 625 should be machined in the annealed condition. As the alloy is

prone to work- hardening, low cutting speeds and appropriate feed rates should be

used and the tool should be engaged at all times. Sufficient chip depths are important

to get below the work-hardened surface layer. The optimum dissipation of heat

through the use of large amounts of appropriate, preferably water containing cooling

lubricants is crucial for a stable machining process.

Welding

When welding nickel-base alloys and special stainless steels, the following

instructions should be adhered to:

Workplace

A separately-located workplace, which is specifically separated from areas in which

carbon steels are being processed, should be used. Maximum cleanliness is required,

and draughts should be avoided during inert gas welding.

Auxiliary equipment and clothing

Clean fine leather gloves and clean working clothes should be used.

Tools and machines

Tools used for other materials must not be used for nickel-base alloys and stainless

steels. Brushes should be made of stainless materials. Processing and machining

equipment such as shears, punches or rollers must be fitted with means (felt,

cardboard, films) in order to avoid material contamination with ferrous particles,

which can be pressed into the surface of the material and thus lead to corrosion.

Welding edge preparation

Welding edge preparation should preferably be carried out using mechanical

methods such as lathing, milling or planing. Abrasive water jet cutting or plasma

cutting is also suitable. In the latter case, however, the cut edge (seam flank) must

be cleanly re-worked. Careful grinding without overheating is acceptable.



Ignition

The arc may only be struck in the weld area, e.g. along the seam flanks or outlets,

and should not be carried out on the work piece surface. Arc striking areas are

prone to corrosion.



INCLUDED ANGLE

The different physical

characteristics of nickel alloys

and special stainless steels are

generally expressed through

lower thermal conductivity and

higher thermal expansion in

comparison with carbon steel.

This should be allowed for by

means of, among other things,

wider root gaps or openings (1-3

mm; 0.04-1.2 in), while larger

included angles (60-70°), as

shown in Fig. 1, should be used

for butt joints owing to the

viscous

nature of the molten weld metal

and to counter- act the pronounced

shrinkage tendency.

Cleaning

Cleaning of the base material in the seam area (both sides) and the filler material

(e.g. welding rod) should be carried out using Acetone.

Welding process

VDM® Alloy 625 can be joined by all conventional welding processes. These include

GTAW (TIG), TIG hot wire, plasma arc, GMAW (MIG/MAG) and MAG-Tandem,

submerged arc welding and SMAW (MMA). For welding, VDM® Alloy 625 should

be in the soft or solution annealed condition and be free from scale, grease and

markings. Pulsed arc welding is the preferred technique. For the MAG process the use

of a multi-component shielding gas (Ar + He + H2 + CO2) is recommended.

When welding roots, sufficient protection of the root needs to be ensured with pure argon

(Ar 4.6) so that the welding seam is free of oxides after welding. Root backing is also

recommended for the first intermediate pass following the initial root pass and in some



cases even for the second pass, depending on the weld set-up.

Any discoloration/heat tint should be removed preferably by brushing with a

stainless steel wire brush while the weld metal is still hot.

Welding parameters and influences

Care should be taken that the work is performed with a deliberately chosen, low heat

input as indicated in Table 6 by way of example. The stringer bead technique is

recommended. The interpass temperature should not exceed 150 °C (302 °F). The

welding parameters should be monitored as a matter of principle.

The heat input Q can be calculated as follows:

U = arc voltage, volts

I = welding current, amps

v = welding speed, cm/min.

POST WELD TREATMENT

Brushing with a stainless steel wire brush immediately after welding, i.e. while the

metal is still hot generally results in removal of heat tint and produces the desired

surface condition without additional pickling. Pickling, if required or prescribed,

however, would generally be the last operation performed on the weldment. Preheating

before welding is generally not necessary.

Availability

VDM® Alloy 625 is available in the following standard semi-finished product forms

Rod and bar

Delivery conditions: forged, rolled, drawn, heat treated, oxidized, descaled resp.

pickled, machined, peeled, ground or polished

Sheet and plate

Delivery conditions: hot or cold rolled, heat treated, descaled resp. pickled



Strip

Delivery conditions: cold rolled, heat treated, pickled or bright annealed

Wire

Delivery conditions: bright drawn, ¼ hard to hard, bright annealed in rings,

containers, on spools and spiders

Other shapes and dimensions such as circular blanks, rings, seamless or

longitudinal-welded tubes and pipes or forgings are subject to special enquiry.



CHAPTER 5

FIXTURES

A fixture is a work-holding or support device used in the manufacturing

industry. Fixtures are used to securely locate (position in a specific location

or orientation) and support the work, ensuring that all parts produced using

the fixture will maintain conformity and interchangeability. Using a fixture

improves the economy of production by allowing smooth operation and

quick transition from part to part, reducing the requirement for skilled labor

by simplifying how work pieces are mounted, and increasing conformity

across a production run.

Types of fixtures

a) Milling fixture

b) Drilling fixture

Figure 5.1: Fixture



5.1 GENERAL CONSIDERATIONS IN FIXTURE

DESIGN

LOADING AND UNLOADING OF PART

Manual lifting or hoisting

Lowering or sliding part into position

Unloading to floor

Use of magazines, conveyors, and chutes for receiving and returning part

Speed of motions

Ease of motions

Safety in manipulations

LOCATING PARTS IN FIXTURE FOR READY

Concentric to an axis

Vertical and horizontal from established surfaces

Vertical and horizontal from discrete points

Other

CLAMPING OF PART

Speed

Size of clamping forces

Direction of clamping forces

Location of clamping forces

Manual or power actuation of clamping elements

SUPPORT OF PART

Against clamping pressure

Against tool forces

Stability of part and avoidance of elastic deformation



POSITIONING CUTTING TOOL RELATIVE TO LOADED

FIXTURE Rotating (“indexing’’)

Sliding

Tilting

COOLANT SUPPLY AND RETURN

CHIPS Removal of accumulated chips

Chip disposal

In order to increase the productivity, a new fixture was proposed in which material was

added, so as to bridge the new dimensions of labyrinth cage.

FIGURE 5.2: FIXTURES WITH CLAMP



CHAPTER 6

MATERIAL SELECTION

1. CAGE BODY- Nimonic material (these are a family of nickel based high temperature

low creep super alloys. These materials generally consist of 50% nickel and 20%

chromium with other additives such as titanium and chromium). The material

composition of cage(NC22DNB) is as shown

C Cr Ni Co Mo Al Ti

Nb Fe Mn Si P S Cu

≤ ≤

≤0.10 20.0- 23.0

balance ≤1.00 8.0- 10.0

0.40 0.40 3.15- 4.15

5.00 0.50 0.50 0.015 0.015 0.07

2. OUTER DIA OF CAGE-Carbide coating In the continuous-combustion HVOF

(High Velocity Oxygen Fuel) thermal spray process, a fuel gas and oxygen are

combusted in a high-pressure chamber reaching temperatures up to 5,600°F (3,093°C).

The resulting hot, high-pressure gas is ejected through a small-diameter nozzle and

accelerated down a long barrel at supersonic speeds. Tungsten carbide powder (or

another powdered coating material, as your project requires) is injected into the nozzle,

where the particles mix with the speeding gases, reaching velocities up to 3,000 feet per

second.

These high speeds impart tremendous amounts of kinetic energy into the powder

particles. When these highly energetic particles strike the substrate, their velocity drops to

zero and they absorb their kinetic energy, which causes them to bond instantly to the

work piece. Subsequent particles arrive almost simultaneously, rapidly building up the

coating. This results in very dense, very adhesive and cohesive tungsten carbide coatings,

with comparatively very high bond strength, low residual stress, low porosity (typically

less than 0.5%), and high wear resistance.

3. INNER DIA OF CAGE-The Plasma Spray Process is basically the spraying

of molten or heat softened material onto a surface to provide a coating. Material in the

form of powder is injected into a very high temperature plasma flame, where it is rapidly

heated and accelerated to a high velocity. The hot material impacts on the substrate



surface and rapidly cools forming a coating. This plasma spray process carried out

correctly is called a "cold process" (relative to the substrate material being coated) as the

substrate temperature can be kept low during processing avoiding damage, metallurgical

changes and distortion to the substrate material. The speed of the jet of plasma which

exits the nozzle is 150m/s and the temperature is 10000o k.

4. DIFFUSER PLATE- It is made of nickel based alloy and its composition is similar

to that of cage. This material is chosen to give the component the required strength to

withstand the high temperatures of the power turbine and it also has good machinability

and weld ability.



CHAPTER 7

METHODOLOGY

OLD PROCESS NEW PROCESS

CTX



CHAPTER 8

BASIC PROCESSES IN MAKING LABYRINTH CAGE

BAR STOCK SLICING: A cylindrical bar of 228 mm diameter is sliced into

sections of thickness 22mm. the cage is made up of nimonic material to withstand the

high temperatures of the engine.This process is done using standard cutter with revolving

blade

FACE TURNING: in this process the material on the biggest dimension of the

cage is done, this is to provide proper contour to the seal, the process is carried out in

lathe as well as in CNC machines.

DRILLING: Drilling is a cutting process that uses a drill bit to cut a hole of

circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often

multi-point. The bit is pressed against the work-piece and rotated at rates from hundreds

to thousands of revolutions per minute. This forces the cutting edge against the work-

piece, cutting off chips from the hole as it is drilled. All the holes drilled are through

holes few are fixing the seal at the right place with the help of screws.

SPOT AND ELECTRON BEAM WELDING: spot welding is a process

where in the metals are joined together with the help of pressure and electricity. In

operation the metals to be welded are kept between two copper electrodes and the

electrodes are pressed to apply pressure to the metal to be welded, current is applied

between two electrodes. Due to this high current the metal melts and the joint is formed

which is a permanent joint. This process follows joules law ie

Q= I2 RT

Where Q is the amount of heat generated

I is the current flowing through the conductor R is the resistance offered by the conductor

T is the time for which the pressure is applied

“Electron Beam Welding is ideal when your application requires a very precise, clean

weld with minimal heating of the material outside the primary area of the weld.

Additionally, EB Welding is excellent for joining dissimilar and hard toweldmetals.



Electron beam welding is the ultimate fusion welding process. Electrons are generated

(via an electron gun) and then accelerated to very high speeds using electrical fields. This

high speed stream of electrons is then focused using magnetic fields and precisely applied

to the materials to be joined. As the electrons impact the materials their kinetic energy is

converted to heat, which causes the metals to melt and flow together. Electron beam

welding generally occurs in a vacuum as the presence of gas molecules can scatter the

beam.

Because of the high voltages involved in EB welding, and the required vacuum, the entire

process is computer controlled and heavily automated. The precise nature of the

technology often calls for specialized fixtures to secure parts for joining, and CNC tables

are commonly used to move the fixtures and work pieces within the welding chamber.

Expensive it is and must be tightly maintained, and the support required by the high

voltage and high vacuum technologies can be demanding. However, electron beam welds

are incredibly precise, strong and pure, the entire process accurately repeatable, and for

many applications and materials, electron beam welding is the best joining technology

there is.



Application Advantages of Electron Beam Welding

Precise Control, Excellent Weld Depth: Weld penetration can be closely controlled —

from a minuscule 0.001 inches to a depth of up to 2 inches.

Small Heat Affected Zone: Electron beam welding has a very high depth-to- width ratio.

This allows for a deep and very narrow heat affected zone, which minimizes material

shrinkage and distortion and allows welds in close proximity to heat sensitive

components.

Strength: EB welds retain up to 95% of the strength of the base materials.

High Purity: Because electron beam welding takes place in a vacuum environment

impurities such as oxides and nitrides are eliminated, and impurities in the materials are

simply vaporized. This results in extremely clean welds perfect for joining a wide

range of metal alloys.

Versatile: Electron Beam welding is excellent for joining refractory and dissimilar metals

which are not weld able with conventional welding process.

Production Capable: Our CNC controlled welders ensure precise control and

repeatability at feed rates from 1 to 200 inches per minute.

PLASMA AND CARBIDE COATING: these processes are mentioned earlier in

the report.

STABALISATION: this process is also called as heat treatment process due to

plasma coating, carbide coating and other welding processes there is a residual stress

induced in the material which if not removed might lead to part failure due to excess

stress. This stress is due to heating and cooling of the part. In operation the part is heated

to a temperature of up to 10500 C in a vacuum furnace due to which the stresses are

relieved and the part is cooled with the help of argon gas at the rate of 200o C/min.



Existing process for cage:

1. Bar stock slicing

In all machining processes, the work piece is a shape that can entirely cover the final part

shape. The objective is to cut away the excess material and obtain the final part.In bar

stock slicing, the raw material is cut into smaller work pieces according to the required

length.

2. Rough turning operations on STC20

The Rough Turning operation allows you to specify:

Longitudinal, Face and Parallel Contour roughing modes

external, internal or frontal machining according to the type of area to machine

delimitation of the area to machine

various approach and retract path types

various lead-in and lift-off options with specific feed rates

recess machining

Various contouring options with specific feed rates.

3. Turning operations on CTX gamma turn mill centre in six stages (operation

numbers 110, 140, plasma, 190, stabilizing, 240, 270 and 300).

Turning centers with rotary-tool capability are sometimes called turn-mill machines. But

at the same time, there is a specific metalworking operation performed on these machines

that rightly deserves to be called "turn-milling." This involves cutting with a rotating

milling tool while the work piece is also rotating.

4. Drilling.

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross- section in

solid materials.

5. Detail part tagging/loading to next assembly as P T Labyrinth cage.

6. Spot welding of flange to cage.

7. Electron Beam welding of deflector to cage.

8. Plasma outer diameter/inner diameter final machining is done in two stages on Montfort

turn Centre.



Modified process for P T labyrinth cage:

1. Bar stock slicing

2. Rough turning operations on STC20

3. Turning operations on CTX gamma turn mill centre in six stages (operation numbers 110,

140, plasma, 190, stabilizing, 240, 270 and 300).

4. Drilling on Vertical machining centre.

5. Spot welding of flange to cage.(spot welding is a process where in the material is heated

on the spot to be welded to temperature of 300 degree Celsius and a force of 3400 N

approx. is applied .The material reaches plastic state due to high temperature and is

forced to attach to the adjacent material (metal) ).

6. Electron Beam welding of deflector to cage.(Electron beam welding is a fusion welding

process were in the material to be welded is bombarded with electrons moving with very

high velocity due to which the materials weld and are fused with each other).

Through slight modification of turning fixtures used on operation numbers

270 and 300 on CTX gamma turn/mill Centre plasma outer diameter/inner diameter

finishing is completed and part was given for further operations(spot welding and

Electron Beam welding after drilling) to confirm the drawing requirements(run out

0.04mm with datum C). Stage inspection is carried out at all operations to ensure the part

geometry. Final part was thoroughly checked for its acceptance.



OPERATION 110



OPERATION 140

PLASMA COATING



OPERATION 190

STABILIZATION PROCESS



OPERATION 240



OPERATION 270

Old Process New Process

The differences between the old process and the new process are highlighted in the above

figures. We can see that apart from the reduction of thickness of the cage the plasma coat

on the outer dia and the inner dia are also being machined i.e. on the outer dia the

dimension 211.5+.05is being reduced to 210.975+.025. And on the inner dia there is not only

reduction on dia but also there a slight change in shape which can be noticed in the

figures. The thickness at the inner dia i.e. of 14mm which was machines to a depth of

142+0.05 after machining the 14mm thickness is divided into two parts, one at 142.92+.05

for a length of 9.5mm from the left and the rest at 143.17+.05



OPERATION 300

Old Process New process

The differences between the old process and the new process are highlighted in the above

figures. Operation 300 is done on the opposite side of the seal (opposite of operation

270).even in this operation we can spot the differences in dimensions of thickness of the

cage i.e.3.6-0.1 to 2.9+_0.05. And we can also see the new contour being formed on the right

side of each process. This new contour is machined later in the old process in Montfort

lathe, where as in the new process this is accommodated in the same machine CTX

gamma turn mill center in the operation 300 thereby saving inventory cost and setup time

at Montfort lathe.



FINISHED DRAWING

In the above figure we can see the drawing of completed labyrinth cage. Here holes are drilled to

fix the seal onto the fixture during operations and also spot weld the flange onto the seal.



EXPECTED OUTCOME

• Elimination of final od/id machining at Montfort turn center.

• Reduction of cycle time.

• Improvement in productivity.

• Cost savings:

Setup time + unit time for

Montfort

operation=2.5hrs+1.5

hrs= 4 hrs/part

Annual requirement=83

Savings worth=83nos*4/part*hourly rate*2800

= Rs 929600/- approximately


CHAPTER 9

CONCLUSION

Productivity improvement of Shakti power turbine labyrinth cage is carried out by change

in the existing process which was used to manufacture the labyrinth cage. The change

was done by fitting all the major processes in the CNC shop thereby reducing the

inventory costs and the setup time. Time saved is time earned. By this we are able to

manufacture the product more efficiently and also able to reduce the costs of

manufacture. Even minor changes like these can play a major role in the growth of a

company.

As we know that in the process of manufacturing a product, many problems might be

faced. A bewildering number of surface engineering techniques are available to the

modern engineer. How do you decide on the correct process for your particular

application? Essentially, an iterative process is required where the application is defined,

the properties required are established, the mechanical design of the coating is performed

and the correct materials are selected for the required properties. The substrate and

interface and surface all need to be engineered to the correct specification, and then

finally, the component is coated and the performance evaluated. If you have made the

correct choices from the correct specification the final product should be successful.

Our project work on productivity improvement of Shakti power turbine labyrinth cage,

gave us successful results.

PRODUCTIVITY IMPROVEMENT OF SHAKTI PT LABYRINTH ...

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