Debolina Mukherjee project Bosch limited

Projects done in BOSCH LTD., Nashik
Debolina Mukherjee
( BE Mechanical)
Department : Process Development : TEF1
1 Abteilung | 19.06.2009 | © Bosch Limited 2009. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung,
Weitergabe sowie für den Fall von Schutzrechtsanmeldungen.
Guidance : Mr. Mendse.M.S.
Mr. Nikam.P.D.

Development:-
Cycle time reduction in WIDMA Machine no. 11411 & 11516 from 48 sec to 32 sec. used for Guide
Bore Gun Drilling operation in DSLA Nozzle Body.
New machine Commissioning :-
• Retco TC 5 and TC6 machine in DSLA Soft Stage used for Drilling guide bore & seat sinking
operation in DSLA Nozzle Body.
• ACE U-Turn I & ACE U-Turn II used for 1st Side and 2nd side turning operation of CRI Injector
Body.
 Tool Trial:-
 Tool Trial:-
• Trial of Grinding Wheel on DN Bahmuller Machine no. 20157 used for external grinding of Shaft,
Shoulder,Collar diameter and finish bottom of DN Nozzle Body.
• Trial of CBN Grinding Wheel on pre-finish station on DN Supfina Machine No.20356 used for
Grinding Top face & maintaining seat depth w.r.t top for DN X Hard Body.
• Trial of face Grinding Wheel on Bahmuller B23 Machine 20536 of CRI CKD area used for face
Grinding of CRI Valve piece.
Trouble shooting:-
• Defect Cause Analysis for Seat defect of CRI CKD Valve Piece manufactured in Bahmuller B23
machine.

Component : CRI Injector Body
Operation : First & Second Side Turning
Make : ACE Designers, Bangalore
Machine Description :
• 2 Axis CNC Turing Centre
• Model µ Turn 500 : 4 Nos.
Commissioning of ACEI & ACE II machine:
•Model µ Turn : 5 Nos.
First Side Turning
Second Side Turning

Sequence of Operation in ACEI (1st side Turning machine):-
CENTRING
ROUGH OD
TURNING
OPERATIONAL
SEQUENCE
TOOL USED
CENTRE DRILL 2.5
X 10 TYPE B
C3-DDJNL-22045-11, DNMG
110408 PF 4015, C3-
LC2085-4038M
LOCATING LOCATING CONE
FINISH OD TURNING
THREAD
ROLLING
DRILLING
REAMING
C3-DDJNL-22045-11,
DNMG 110408 PF 4015,
C3-LC2085-4038M
FETTE THREAD
ROLL T27(M15X
0.5 MM)
CARBIDE DRILL
DIA.5.5 MM
CARBIDE
REAMER 6 MM

OD ROUGHTURNING
OD FINISH TURNING
M27X 1 THREAD ROLLING
STEP DRILLING
OPERATION TOOL USED
Ø 6 PILOT DRILL
DNMG 11 0408-PM-4225
DNMG 110408 PF4015
THREAD ROLLERS M27X1
STEP DRILL Ø PILOT DRILL
Ø 6 PILOT DRILL
Sequence of Operation in ACEI (2nd side
Turning machine):-
ROUGH BORE DRILLING
ROUGH SINKERING
INTERNAL THREADING M17X1
FRESBEE OPERATION
FINISH SINKERING
Ø 6 PILOT DRILL
CPMT 060204 PM4025
Ø 6 PILOT DRILL
ROUGH SINKER
KVCGT 030204-PM2WXK10
R166.0 L- MM01-100
FINISH SINKER

List of Dimension to be
checked in 1st side Turning :-
Confirmation of Quality
parameters :-

List of Dimension to be checked
in 2nd side Turning :-
Confirmation of Quality
parameters :-

Activities undertaken during commissioning
ACE I & II machines:-
Cmk No of characteristics where CmK
1.67 to 2.0 to 5.0 to Above
Status ACE machines
Quality : Capability study for all 9 machines Over
Installation
Commissioning
Functional Checking
Machining
1.67 to
2.0
2.0 to
5.0
5.0 to
10.0
Above
10.0
ACE1 2 (11%) 5(29%) 6(35%) 4(23%)
ACE2 1 (4%) 7(30%) 5(21%) 10
(43%)
Availability : 8 Hr Run for all machines is over
• Technical Availability more than 95 %
Final Acceptance…Capability test
Availability Test…8hours run
Associates training
Optimization : Process parameters

Debolina Mukherjee project Bosch limited

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