With Smart People and Smarter Engineering

Toughest Machining Challenge Ever (Fuel Injection Component)

Challenge: Diameter 8 having a tolerance of 10 microns & concentricity of both ends to be within 30 microns. The length of Diameter 8 is 138mm means an L/D ratio of 17:1. If we check in the design, Diameter 8 has intermittent cuts. Bore tolerance 10 microns, concentricity over 138 mm of 30 microns, these complexities further aggravated by an intermittent cut
- "A nightmare for an engineer".

Innovation: A unique combination of cutting tools beginning with drilling operation, followed by primary & secondary reaming, has been developed and established by the SOM Engineering team. The European counterpart used to machine these features on large size HMCs. Here in INDIA, we have been performing these operations on VMCs with 4th Axis.

Result: Accuracy & precision sustained for the last four years.

Simulation of LPDC machine in Die maintenance.

Challenge: High Die Changeover times on Low Pressure Die Casting Machine for proper alignment of sliders & sand cores.

Innovation: A die simulator was introduced on which the alignment of sliders & sand cores was pre-checked before loading the die on the machine.

Result: Drastic reduction in setup changeover time, leading to increased availability of the machine. In a further step, this simulator is being used to train operators before the actual handover of the machine.

Two-layer Die Coating Process

Challenge: Frequent Die changeover, i.e. every three days for re-coating for prevention of defects like soldering, catching.

Innovation: Two-layer die-coating process designed and implemented, i.e. all the plates of the cores were now being applied two coats against previous single layer application.

Result: Die coating interval has been changed from after every 9 shifts to after every 18 shifts thereby availability of machine has been enhanced drastically.

Seat Check Blockage Elimination

Seat check While placing the component on machining fixture, it is necessary that the component rests completely on the rest pads. Seat check in the form of compressed air orifice is provided for giving feedback of complete resting.

Challenge: Blockage of seat check orifice by dirt/burr, making it non-functional, leading to missed detection of improper loading of the component on machining fixture generating defects.

Innovation: Air flush mechanism with 5-6 bar pressure introduced after every cycle, designed in-house by SOM engineers.

Result: Uninterrupted and smooth functioning of seat checks mechanism preventing subsequent machining defects.