Chip Management in Milling and Drilling of Ductile Cast Iron
(2023) MMTM05 20231Production and Materials Engineering
- Abstract
- This paper presents a comprehensive cross-functional analysis of machining operations for ductile cast iron components in the automotive industry, focusing on the problem of chip carryover and its impact on downstream processes. The research aims to understand the role of machining and identify the source of the issue, by analyzing different machining sequences and the chips that affect the final product or subsequent production stages. To achieve this, the study initially focuses on a 5-axis machining production cell, evaluating the current choice of tooling systems and peripheral processes such as cooling, lubrication, and chip removal solutions. Based on empirical findings, the study presents newly developed solutions to address and... (More)
- This paper presents a comprehensive cross-functional analysis of machining operations for ductile cast iron components in the automotive industry, focusing on the problem of chip carryover and its impact on downstream processes. The research aims to understand the role of machining and identify the source of the issue, by analyzing different machining sequences and the chips that affect the final product or subsequent production stages. To achieve this, the study initially focuses on a 5-axis machining production cell, evaluating the current choice of tooling systems and peripheral processes such as cooling, lubrication, and chip removal solutions. Based on empirical findings, the study presents newly developed solutions to address and minimize the problem of chip carryover in the current production context. These solutions include implementing new sequences of operations and optimizing peripheral processes to prevent chip buildup and reduce the need for manual intervention. The results of the study demonstrate the effectiveness of the proposed solutions in reducing production costs and improving product quality. Overall, this research highlights the importance of a broad and cross-functional approach for developing and implementing improved production strategies. By providing an alternative to a costly manufacturing issue, this study contributes to the ongoing efforts to improve the efficiency and sustainability of manufacturing processes in the automotive industry. (Less)
- Popular Abstract
- This paper presents a study focused on addressing the issue of chip carryover in machining operations for ductile cast iron components in the automotive industry. Chip carryover occurs when the metal chips resulting from a machining process such as drilling or milling, are not correctly removed from the workpiece. Hence, these small parts of metal remain with the part and get carried over to later stages of the manufacturing process, potentially causing problems.
To achieve this, the study conducts a comprehensive and cross-functional analysis of machining operations and their impact on downstream processes. A specific focus is placed on a milling center, evaluating tooling systems, cooling, lubrication, and chip removal solutions. By... (More) - This paper presents a study focused on addressing the issue of chip carryover in machining operations for ductile cast iron components in the automotive industry. Chip carryover occurs when the metal chips resulting from a machining process such as drilling or milling, are not correctly removed from the workpiece. Hence, these small parts of metal remain with the part and get carried over to later stages of the manufacturing process, potentially causing problems.
To achieve this, the study conducts a comprehensive and cross-functional analysis of machining operations and their impact on downstream processes. A specific focus is placed on a milling center, evaluating tooling systems, cooling, lubrication, and chip removal solutions. By analyzing empirical findings, the research proposes innovative solutions to minimize chip carryover, ensuring improved product quality and reduced production costs.
The newly developed solutions involve implementing optimized sequences of operations and peripheral processes to prevent chip accumulation, thereby reducing the need for manual intervention. Through the implementation of these solutions, the study demonstrates their effectiveness in enhancing the efficiency and sustainability of the manufacturing processes conducted at this site.
This research underscores the significance of a holistic and cross-functional approach in developing and implementing improved production strategies. By providing an alternative to costly manufacturing issues, this study contributes to the ongoing efforts to enhance the efficiency and sustainability of manufacturing processes in the automotive industry, benefiting both the industry and the broader public. (Less)
Please use this url to cite or link to this publication:
http://lup.lub.lu.se/student-papers/record/9124766
- author
- Jönsson, Alexander LU and Aliboni, Giacomo
- supervisor
- organization
- course
- MMTM05 20231
- year
- 2023
- type
- H2 - Master's Degree (Two Years)
- subject
- keywords
- Chip Carryover, Chip Management, Ductile Cast Iron, Chip Removal, Chip Asportation, Milling, Drilling
- report number
- CODEN:LUTMDN/(TMMV-5350)/1-116/2023
- language
- English
- id
- 9124766
- date added to LUP
- 2023-06-15 09:44:06
- date last changed
- 2023-06-15 09:44:06
@misc{9124766,
abstract = {{This paper presents a comprehensive cross-functional analysis of machining operations for ductile cast iron components in the automotive industry, focusing on the problem of chip carryover and its impact on downstream processes. The research aims to understand the role of machining and identify the source of the issue, by analyzing different machining sequences and the chips that affect the final product or subsequent production stages. To achieve this, the study initially focuses on a 5-axis machining production cell, evaluating the current choice of tooling systems and peripheral processes such as cooling, lubrication, and chip removal solutions. Based on empirical findings, the study presents newly developed solutions to address and minimize the problem of chip carryover in the current production context. These solutions include implementing new sequences of operations and optimizing peripheral processes to prevent chip buildup and reduce the need for manual intervention. The results of the study demonstrate the effectiveness of the proposed solutions in reducing production costs and improving product quality. Overall, this research highlights the importance of a broad and cross-functional approach for developing and implementing improved production strategies. By providing an alternative to a costly manufacturing issue, this study contributes to the ongoing efforts to improve the efficiency and sustainability of manufacturing processes in the automotive industry.}},
author = {{Jönsson, Alexander and Aliboni, Giacomo}},
language = {{eng}},
note = {{Student Paper}},
title = {{Chip Management in Milling and Drilling of Ductile Cast Iron}},
year = {{2023}},
}