1. 1 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D NEW PRODUCT DEVELOPMENT NEW PRODUCT DEVELOPMENT By V.Neville Gnanaraj

2. 2 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Magna Digitech is in the Business of Providing Engineering Service to the Mechanical Engineering Domain. Incorporated in 2003 Core competency in Mechanical Engineering Domain 40 Man Years Experience Software Available ProE Wildfire 5 Solidworks 2013 Unigraphics NX AutoDesk Products SolidEdge V18 Magmasoft 5.2 Magna Digitech can provide the following services Mechanical Engineering Legacy conversion to 2D drawings Developing 3D models Reverse Engineering Finite Element Analysis Jigs & Fixture Design Foundry Casting design Tool Model Conversion from Fabrication to Casting Casting Simulation

3. 3 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D New Product Development - Expectations Right First Time and Every Time On Time Product Development Producing The Casting at Right Cost How to achieve this??

4. 4 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Tool Design Method Design Design review and Final Output Tool Manufacturing and Review Process Parameters Fixing Check Points to be Validated before Trial Trial Process Validation of Trial by User Departments Detailed Action Plan Handing Over to Production New Product Development - Process

5. 5 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D New Product Development - Plan

6. 6 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Component Name: Lever Cover (Ductile Iron) Brief Description and Technical Challenges. –Casting weight 2.6Kgs –Wall Thickness 6mm +/- 0.5 –X-ray – Level 2 Case Study - 1

7. 7 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D L0 Results

8. 8 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Top Bottom Hotspot Results

9. 9 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Final Simulation Results

10. 10 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Filling Results

11. 11 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Solidification Results

12. 12 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Hotspot Results

13. 13 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Porosity Results

14. 14 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Actual Results Samples Sent and released for production. Unfortunately we are not able to complete the schedule due to high in-house rejection..

15. 15 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Initially we have cleared the design for tool manufacturing considering 1.Method validated through simulation 2.Proper core print provided at center of to avoid core tilt and further bottom of chill will rest on mold. Reason for Rejection 1.Wall Thickness Variation

16. 16 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Analysis for Rejection 1.Cavity 2 & 4 has less wall thickness at top and cavity 1 & 3 has less wall thickness in bottom. 12 43

17. 17 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Cause for Rejection 1.Metal flow direction which triggers the lift of core 12 43 But we have anticipated the same problem during our design stage and assumed this will be taken care by seating of chill bottom to mold.

18. 18 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Real Cause for Rejection 1.Variation in chill ht. 2.All the chills ensured - it should not exceed its maximum height and at the same time no record for minimum size. Rejection due to wall thickness variation eliminated after removing chills not meeting the spec.

19. 19 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Component Name: Central Housing ( Grey Iron ) Brief Description and Technical Challenges. –Casting weight 1.3Kgs –No defect after machining Case Study - 2

20. 20 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Shell Core Core weight 0.62kgs

21. 21 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D L0 Results

22. 22 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Hotspot Results

23. 23 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Final Simulation Results

24. 24 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Filling Results

25. 25 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Solidification Results

26. 26 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Major rejection is due to blow hole.. Actual Results

27. 27 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Analysis and Action 1.Blow hole defect due to gas generation in core 2.Various type of resin coated sand tried 3.Core gas vents provided in parting line. Result 1.There was an improvement. 2.But Not to the expected level.

28. 28 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Real Cause for Blow hole 1.The resin coated silica sand is not suitable for component like this. 2.Changed the process – Core with resin coated quartz sand. 3.Drill holes provided in core print to the possible extend. Rejection due to Blow hole eliminated by changing core process

29. 29 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D Lesson Learnt. 1. Tools like simulation software can help to achieve result. ( say 90%) 2. Simulation tools can describe the system behavior under given conditions. 3. Validate the defined process parameters before using them. 4. Select appropriate process to meet the target.

30. 30 MAGNA M A G N A DIGITECH INDIA PRIVATE L I M I T E D T H A N K Y O U