No abstract

Manufacturing companies are continuously facing the problem of operating their manufacturing and assembly process, in order to deliver the required production rates with high quality, it is required to makes the product customization and short time to market increases the competition among the global manufacturer. The module has analyzed in RANE Madras Company in Mysore. This paper describes the assembly automation of HSU (Hydrostatic steering unit) using poka yoke technique over manual assembly process by considering mistakes in the manual process and cost, quality, production, lead time under demand fluctuation. The methodology includes FMEA of manual assembly process. The selection of final concept by generating 4 concepts using Pugh matrix method and finally detailed design of selected concept has been well tested. As per the obtained results, it is possible to reduce the human mistakes up to zero percent and reducing the cycle time from 20 seconds to 10 seconds.

Brazing of ceramic and metal components is an emerging manufacturing technology in which a furnace or a heat source is used to join the substrates using a brazing filler material. Brazing of ceramic and metal has received considerable attention in the field of nuclear reactor, aerospace, automobile, medical and electrical engineering. A brazing alloy can either be a conventional brazing alloy which requires the ceramic surface to be metallized or an active brazing alloy which does not require metallization. A sound interfacial adhesive bond is formed during the process. The typical active elements required in the brazing alloy for bonding of alumina are Ti and Zr. It is expected that since Ti is present in Ti6Al4V, a copper-silver alloy (Cusil™) without an active element can be used for brazing. The Ti substrate itself could provide the reactive element because of dissolution. Vacuum brazing of alumina and titanium with Cusil sheet has been carried out to analyze the characteristics of the joint. Behavior of the joint under different temperature conditions has been studied by thermal cycling of the joint. Uniformity of the joints is confirmed by observing the Scanning electron microscope (SEM) images. The elements and phases present in the joint interface are observed by energy dispersive spectroscopy (EDX) and X-ray diffraction (XRD) analyses. The maximum shear strength obtained in the brazedTi6Al4V/Cusil sheet/alumina joint was 102MPa and the average shear stress was found to be 70±3 MPa. The micro-Vickers hardness test showed that the micro hardness of the interface was lower than the substrates.

The joining of ceramic to structural alloys has received much attention in recent years because of its potentially attractive properties. In the present investigation alumina which is a ceramic has been brazed with titanium alloy (Ti6Al4V) using KM72(Ag/Cu) filler material.The study has been carried out using CO2laser gas in argon inert atmosphere. Uniformity of the brazed joints has been observed in scanning electron micrographs. The elements and phases present at the joint interface have been characterized by EDX and XRD spectra analysis. As per the experimental observation, the phases present in the Ti6Al4V/KM72/alumina joint are Cu3TiO4, Cu3Ti2,CuO, Ti2Cu, CuTi, and Cu4Ti3. The effect of brazing process parameters on the shear strength of the brazed joint has been studied and maximum shear strength observed at brazing power of 330 watts and speed 300 mm/min is 4±0.5MPa. Micro-hardness values of the brazed interface indicate that the interface is softer than the substrate.