STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
PROJECT NAME CHARGE AIR PIPE
SCOPE To design and convert the present
fabricated Charge Air Pipe to Ductile
Iron Casting
USED IN Tier II Locomotive Engine
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Constraints in Fabrication

1. To fabricate one component, it requires to
   assemble more than 40 components.
2. Ensuring the welding strength in all areas is a
   constraint
3. Extensive fixture required to weld so that to
   meet the Dimension accuracy.
4. Each sub component will be considered as a fresh
   setting piece For machining.
5. Excessive Time consuming for welding and
   machining
6. Since it has 40 sub components material property
   to be ensured for all parts.

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Key areas Identified by MagnaD

• The material property should meet both form , fit
  and assembly function
• The casting should pass radiographic quality ASTM
  E446 Level II
• The casting should pass 100 leak test to ensure
  there is no leakage for both water and air media.
  
• 6bar for water passage area for 5 minutes and
• 4.5bar for air passage area for 5 minutes

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Key areas Identified by MagnaD cont.

• Wall thickness variation should be within 1.5mm
  (total tolerance) to the entire length (952.0mm)
• During machining, to ensure the dimensions are
  well within specified limit.
• Face parallelism within 0.2mm (length 940.00mm)
• All holes to be within positional tolerance of
  0.4mm in total and 0.1mm for one side.
• 6. Casting and machining feasibility.

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Various stages of projects

1. Preparation of 3D model for discussion and to get
   ideas from various departments.(APQP)-Brain
   Storming
2. Preparation of casting model.
3. Pattern, core box, assembly design and 3D model
   preparation.
4. Casting model used to freeze the methoding design
   through simulation software.
5. Machining fixture design.
6. Leak test fixture design.
7. Dimension inspection check sheet.

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
3D model preparation for final casting
This 3D model is fully parametric so that it can
be easily get updated based on the suggestions
from user departments without affecting the final
customer specification.
Total weight of the casting 186kgs
(410lbs) Overall size 400x600x952mm
(15.75x23.62x37.48inch).
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Pattern and core box Model

• From the casting model best possible parting line
  for pattern and core box finalized.
• All necessary drafts and fillets added in the
  casting area.
• Proper core locks provided to avoid wall
  thickness variation.
• Machining references also considered during
  pattern and core box design to ensure the casting
  to machined dimensions.

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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Pattern Model.
Top Pattern
Bottom Pattern
Core print lock
Core print
Sand collector
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Core box Model.
Core Box Top
Core-1
Core-2
Core Box bottom
Core-3
Core Box Loose piece
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION
Casting methoding design
Casting methoding for pouring also finalized
with the help of simulation software. By this
we are able to provide the best feeding solution
to meet the x-ray quality ASTM E446 Level II
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION

• Final component
• From all the effort the final component comes all
  right in the first shot.

Final assembly Model
Final assembly Casting
2820mm 111.0inch
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STEEL FABRICATTION TO DUCTILE IRON CASTING
CONVERSION

• Advantages to Customer
• Total cost saving per component 33
• Total time saved 50
• Single point contact for entire assembly
• Reduction in transportation time

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STEEL FABRICATTION TO STEEL CASTING CONVERSION
PROJECT NAME MAGNET FRAME
SCOPE To design and convert the present
fabricated Magnet frame to Steel Casting
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STEEL FABRICATTION TO STEEL CASTING CONVERSION

• Varies steps
• First we have made a 3D model of fully
  machined fabricated one and from there we have
  started identifying small components.
• Due to section thickness variation we have
  spitted the parts into two.
• To compare the casting behavior first we have
  analyzed the fabricated part and then our casting
  part. From the results we fine tuned our casting
  to meet the requirement.

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STEEL FABRICATTION TO STEEL CASTING CONVERSION
Part of Magnet frame steel Casting
Magnet frame Fabricated
Meshing of Magnet Frame