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    Project Report Middle

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    M.Saravana Kumar..M.E
    The document discusses problems faced with the wire drawing machine IVD 800 at a manufacturing unit. The machine could not run at high speeds and could only draw wire up to 14.6 mm diameter, instead of the maximum 18 mm capability. To improve capacity, a third roller was proposed to better support the wire. Analysis using a fishbone diagram and force field analysis identified wire support as the key issue. A design was created for a third roller with determined dimensions to strengthen wire holding and allow higher speeds and larger wire diameters, improving machine efficiency.

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    Project Report Middle

    Uploaded by

    M.Saravana Kumar..M.E
    169 views5 pages
    The document discusses problems faced with the wire drawing machine IVD 800 at a manufacturing unit. The machine could not run at high speeds and could only draw wire up to 14.6 mm diameter, instead of the maximum 18 mm capability. To improve capacity, a third roller was proposed to better support the wire. Analysis using a fishbone diagram and force field analysis identified wire support as the key issue. A design was created for a third roller with determined dimensions to strengthen wire holding and allow higher speeds and larger wire diameters, improving machine efficiency.

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    Project Report Middle

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    The document discusses problems faced with the wire drawing machine IVD 800 at a manufacturing unit. The machine could not run at high speeds and could only draw wire up to 14.6 mm diameter, instead of the maximum 18 mm capability. To improve capacity, a third roller was proposed to better support the wire. Analysis using a fishbone diagram and force field analysis identified wire support as the key issue. A design was created for a third roller with determined dimensions to strengthen wire holding and allow higher speeds and larger wire diameters, improving machine efficiency.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    169 views5 pages

    Project Report Middle

    Uploaded by

    M.Saravana Kumar..M.E
    The document discusses problems faced with the wire drawing machine IVD 800 at a manufacturing unit. The machine could not run at high speeds and could only draw wire up to 14.6 mm diameter, instead of the maximum 18 mm capability. To improve capacity, a third roller was proposed to better support the wire. Analysis using a fishbone diagram and force field analysis identified wire support as the key issue. A design was created for a third roller with determined dimensions to strengthen wire holding and allow higher speeds and larger wire diameters, improving machine efficiency.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 5

    i

    ABSTRACT

    The Raw Materials division of TVS Sundram Fasteners, Madurai Unit was

    experiencing a problem with a wire drawing machine named Invert Vertical

    Drawing Machine IVD 800. The workers were not able to run the machine at high

    speed and also the diameter of the wire fed into the machine was limited to 14.6

    mm as against the maximum diameter of 18 mm, that the machine was capable. In

    order to increase the capacity of the machine, we need to introduce a roller, in

    addition to the existing two rollers. The rollers support the wires and are

    responsible for holding the wires strongly. If the wire is held strongly, we can

    increase the speed of the machine and also increase the diameter of the wire that is

    fed in the machine. The third roller is introduced after discussing various solutions

    and also finding the need by using Forced Field Analysis. We construct geometry

    for finding out the changes we need to make in order to introduce the third roller.

    Finally, a design is created for implementation of third roller which will improve

    the efficiency of the machine, which will ultimately improve the amount of the raw

    material processed in the unit.


    ii

    TABLE OF CONTENTS

    CH.NO TITLE PAGE. NO


    ABSTRACT i
    LIST OF FIGURES iv
    LIST OF UNITS & NOMENCLATURE v

    1. INTRODUCTION 1
    1.1 ABOUT THE COMPANY 1
    1.2 GLOBAL PRESENCE 2
    1.3 ENVIRONMENTAL POLICY 3
    1.4 PRODUCTS 3
    1.5 AWARDS 4

    2. PROCESS CARRIED OUT IN THE INDUSTRY


    2.1 RAW MATERIAL RECEPTION 8
    2.2 WIRE ANNEALING 8
    2.3 WIRE PHOSPHATING 9
    2.4 WIRE DRAWING 11
    2.5 FORGING PROCESS 12

    3. PROBLEM DESCRIPTION 14
    3.1 ABOUT INVERT VERTICAL DRAWING
    MACHINE IVD 800 14
    3.2 WORKING OF THE MACHINE 14
    3.3 PROBLEM FACED IN THE MACHINE 15
    iii

    4. PROBLEM SOLVING METHODOLOGY 16


    4.1 FISHBONE DIAGRAM 16
    4.2 HOW TO USE THE TOOL 17
    4.3 FISHBONE DIAGRAM FOR POOR
    PERFORMANCE OF IVD 800 19
    4.4 FORCE FIELD ANALYSIS 21
    4.5 FORCE FIELD DIAGRAM
    FOR IVD 800 22

    5. SOLUTION
    5.1 SUGGESTED SOLUTION 24
    5.2 DETERMINATION OF DIMENSIONS
    FOR THE THIRD ROLLER 25
    iv

    LIST OF FIGURES

    Fig No Description Page No


    1.1 Sundram Fasteners Global Presence 2
    1.2 Manufacturing locations in India 4
    2.1 Process Carried Out in the Industry 7
    2.2 Process carried out in Wire Phosphating 9
    2.3 Concept of Wire Drawing 12
    2.4 Concept of Forging 13
    3.1 Model of IVD 800 13
    4.1 Fishbone diagram for IVD 800 19
    4.2 Force Field Diagram for IVD 800 22
    5.1 Diagram for introducing third roller 24
    5.2 Top View of Original Roller Support 25
    Used for Rollers 1, 3
    5.3 Top View of Modified Roller Support for Roller 2 26
    v

    UNITS & NOMENCLATURE

    1. IVD Invert Vertical Drawing Machine

    2. mm millimeter

    3. m/min meter per minute (amount of wire drawn)

    4. cm centimeter

    5. C degree Celsius (unit of temperature)

    6. UTS- Universal Testing Machine

    7. rpm Revolutions

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