Success Stories



Problem

Lobes were observed when doing finish Grinding operation on orbital grinding machine.

Investigation Carried Out

Vibration Spectrum Analysis of machine.

Outcome of Investigation

The source of vibration is identified to be coolant transfer pump, which is connected to the machine.

Recommended Solution

Change the coolant motor impeller.

Final Outcome

Surface finish has improved, and no lobes were observed.

Problem

Vibration levels of the ventilation fans used in subway tunnels were more than the manufacturer recommended values.

Investigation Carried Out

Vibration Spectrum Analysis of TVF

Outcome of Investigation

The source of vibration is identified to be orientation of dampener connected on the TVFs.

Recommended Solution

Change the orientation of the support dampener by 90degrees.

Final Outcome

Vibration levels were reduced drastically and it is well within the manufacturer recommended values.

Problem

Repeatability error of the grinding machine was found to be more.

Investigation Carried Out

Analysis using Laser interferometer

Outcome of Investigation

Telescopic cover and motor tuning was found to be the source.

Recommended Solution

Correct the telescopic cover issue and to tune the system..

Final Outcome

Repeatability error were achieved less than 1 micron.

Problem

Chatter marks were observed when doing Facing operation on Vertical Turning Lathe.

Investigation Carried Out

Vibration Spectrum Analysis of machine.

Outcome of Investigation

The source of chatter is found to be spindle bearings without dismantling the spindle using frequency analysis.

Recommended Solution

Machine supplier was advised to change the bearing.

Final Outcome

Surface finish has improved, and no chatter marks were observed.

Problem

Vibrations were found to be more on a high speed die mould milling machine.

Investigation Carried Out

Mode shape analysis of the Ram with Spindle.

Outcome of Investigation

The source of vibration is found to be because of the natural frequencies and related dynamics of the machine.

Recommended Solution

Redesign the spindle Ram with improved stiffness on selective portions.

Final Outcome

Manufacturer has matched the experimental mode shapes data with analytical data by using FEA, Ram was redesigned in FEA for better dynamic stiffness.

Task

To increase the auto component’s fatigue life.

Investigation Carried Out

Residual Stress Analysis

R&D Work Carried Out

The manufacturing process was modified to induce different residual stresses for better fatigue life.

Final Outcome

Component’s fatigue life has increased.

Problem

Chatter marks were observed when doing boring operation on VTL.

Investigation Carried Out

Vibration Spectrum Analysis of machine.

Outcome of Investigation

The source of chatter is found to be tool holder design, using frequency analysis.

Recommended Solution

Change the boring holder design.

Final Outcome

Vibration levels have reduced drastically and finish has improved significantly.