Innovative Burr Removal Green Technology For Piston Ring

Project initiation date: 02/10

Challenge

Burr problem was observed at customer end during first time development & supplies of Oil Ring with Nodular Cast Iron (Ductile) for prestigious American customers.

24 nos. found during sample inspection of P/N 7N7078 & 15 nos. found during sample inspection of P/N 9S7788(D22-3).

It was noted that inspite of 3 stage burr removal process (ultrasonic cleaning,+Id burshing+inspection) there were customer observations.

Extensive manpower had to be deployed to manually re-inspect and remove the burr by knife edge file, as the productivity was very less, only 300 rings per shift.

Manual removal of burr had following problems:

1. No fool proofing. Even single burr in a lot of rings not acceptable.
2. Safety of operator- First aid incidences of cut in finger from the blade
3. High lead time due to slow manual burr removal process
4. Rusting on rings required to be removed by brushing.
5. Low productivity
6. Quality issues of peel-off/ distort the ring

Engineering solution to global customer was important to make foot print in technologically advanced & huge potential US market (Sales 2011-12: 5 million US$).