MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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. Constraints in Fabrication STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 1.The material property should meet both form, fit and assembly function 2.The casting should pass radiographic quality ASTM E446 Level II 3.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 Key areas Identified by MagnaD STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 4.Wall thickness variation should be within 1.5mm (total tolerance) to the entire length (952.0mm) 5.During machining, to ensure the dimensions are well within specified limit.  Face parallelism within 0.2mm (length mm)  All holes to be within positional tolerance of 0.4mm in total and 0.1mm for one side. 6.Casting and machining feasibility. Key areas Identified by MagnaD – cont. STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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. Various stages of projects STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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). 3D model preparation for final casting STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d  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. Pattern and core box Model STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Pattern Model. Top Pattern Core print Bottom Pattern Sand collector Core print lock STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Core box Model. Core-1 Core-2 Core-3 Core Box bottom Core Box Top Core Box Loose piece STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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 Casting methoding design STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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 STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Advantages to Customer  Total cost saving per component – 33%  Total time saved – 50%  Single point contact for entire assembly  Reduction in transportation time STEEL FABRICATTION TO DUCTILE IRON CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d STEEL FABRICATTION TO STEEL CASTING CONVERSION PROJECT NAME: MAGNET FRAME SCOPE: To design and convert the present fabricated Magnet frame to Steel Casting

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d 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. STEEL FABRICATTION TO STEEL CASTING CONVERSION

MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d Magnet frame Fabricated Part of Magnet frame steel Casting Meshing of Magnet Frame STEEL FABRICATTION TO STEEL CASTING CONVERSION