Calander thickness measurement and Analysis.pdf

8/10/2019 Calander thickness measurement and Analysis.pdf

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Presented by:

ALAWATHTHAGE G.C. (RU/E/2009/004)

KULATHUNGA H.G.G. (RU/E/2009/095)

RATHNAYAKA R.M.P.P.K. (RU/E/2009/148)

CALENDAR THICKNESS MEASUREMENT

and

ANALYSIS

SECOND PROGRESS


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PRESENTATION OUTLINE

CALENDARING PROCESS

INTRODUCTION TO THE PROBLEM

LITERATURE REVIEW

MEASURING AND ANALYSIS OF CALENDAR LAYER THICKNESS

MEASURING AND ANALYSIS OF CALENDAR ROLLER SURFACE

CONCLUSIONS OF INVESTIGATIONS

REASONS FOR ISSUE

AMOUNT OF MATERIAL WASTE

SOLUTION


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Why Calendaring in Tyre Manufacturing?

For making inner liner & calendar layer

What is Calendaring Process?

Calendaring process

CALENDARING PROCESS IN TYRE

MANUFACTURING


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INTRODUCTION TO THE PROBLEM

Research Problem

Cross Section of Calendar Layer

There is no any scientific investigation carried out to related to the

issue

project targets to find a most suitable solution and improve the

productivity, working efficiency as well as saving of valuable material


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similar type of issue in metal strip manufacturing, but in that case,

metal strip thickness is varying along length of the metal strip.

Research is done by T. Widmaier, T. Salmela, P. Kuosmanen, J.

Juhanko, P. Karha and J. Uusima.

Try to understand the phenomena behind the rolling force variations

seen in the rolling force measurements. The aim was to reduce the periodic rolling force variation and to

study how this affects the thickness variations of the steel strip.

LITERATURE REVIEW

Thickness Variation Along Length of Metal Strip


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RESEARCH METHODOLOGY

1. Measuring the calendar thickness.

2. Data analysis and calendar surface mapping.

3. Measuring the calendar roller surface variation.

4. Data analysis and calendar roller surface mapping.

5. Impact of the side cutters to the issue.

6. Effect of tension variation and sagging of the calendar layer.

7. Cost estimation for the material waste.

8. Finding a most affordable solution to solve the issue.


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Specifications of Obtained a inner liner

Thickness Width Length2mm 1500mm 4250mm

Preparations for the Taking Measurements

Decided to measure the thickness of the calendar from the distanceof 5cm.

To achieve that firstly we divide the layer in widthwise in to 5cm

partitions and then lengthwise.

Calendar Thickness Measurement, Data Analysis and

Sur face Mapping


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5cm square divisions Measuring the Layer Thickness

Thickness Gauge

Used Microsoft excel and MATLAB software

packages for Data Analysis and Surface Mapping


Sur face Mapping


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Calendar roller sur face var iation Measurement, Data

Analysis and Sur face Mapping

A special methodology for roller surface measurement.

Measuring process

Marking Measuring Coordinates on the roller and reference edge

Paper Strip with Coordinates pasted on the roller

Reference Edge with Coordinates System


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Measuring process

The Reference edge mounted to the machine using brackets.

Adjust the distance by moving the reference edge through the slots.

Measure the distance between reference edge & roller surface by

using two feeler gauges sets.

Reference Edge Mounting to the MachineFeeler Gauge Set


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Used Microsoft excel and MATLAB software packages for Data

Analysis and Surface Mapping




Impact of the side cutters to the issue

visually inspected the surfaces of both calendar rollers.

Compare the surfaces.

Effect of tension var iation and sagging of the calendar layer

Based on the pattern of thickness variation.


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Cost estimation for the mater ial waste

Measure the weight of a sample.

Calculate the density.

Calculate the excess material per unit length.

Estimate the annual loss.

F inding a most affordable solution to solve the issue

Changing the order of roller location.

Roller grinding or refurbishment.

Improvement for cutter mounting.

Roller replacement.


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OBSERVATIONS, RESULTS & DISCUSSION

0

5

10

15

20

25

30

0

5

10

15

20

25

30

1.5

2

2.5

3

WIDTH

SurfacePlot ofCalendarLayer First Measurement

LENGTH

T

HICKNESS(mm)

1.9

2

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

0

5

10

15

20

25

30

0

5

10

15

20

25

30

1.5

2

2.5

3

WIDTH

SurfacePlot ofCalendarLayerSecondMeasurement

LENGTH

THICKNESS(mm)

1.9

2

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

0

5

10

15

20

25

30

0

5

10

15

20

25

30

1.5

2

2.5

3

WIDTH

SurfacePlot ofCalendarLayerThirdMeasurement

LENGTH

THICKNESS(mm)

1.9

2

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

Surface Plots of Calendar Layer


Sur face Mapping

Similar pattern of variation along the width.

Thickness vary from 1.9mm to 2.7mm.

No any considerable variation along the length


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Significant variation along the length of the calendar roller

Roller Surface Plot


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Defected Areas of Calendar

Layer

Defected Areas of Calendar

Roller

Surface Plot of Calendar Layer Surface Plot of Calendar Roller


Comparison of resul ts

Defected Areas are similar in both calendar surface and roller surface

variation.


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Difference of Roller Surface and Calendar thickness


Comparison of resul ts

Difference of the calendar roller surface and the average calendar

thickness is having a linear relationship.

It is proven that the issue is occurred due to the surface variation of

the roller surface


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Damaged area ofroller

Side Cutter

Direct Contact of Cutter Roller

Roller Contact

with cutters

Roller without

Contact cutters

Impact of Cutters


Impact of the side cutters to the issue

The roller which is directly contact with cutters are severely damaged

while other one in good condition.

Effect of tension variation and sagging of the calendar layer

No variation along the length of the calendar layer.

No impact of tension variation or calendar layer sagging.


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It is average loss per day 580kg and average cost of it is 350Rs.

580*350 = Rs. 203000


Cost estimation for the mater ial waste

Density of compound 1207.79Kgm^(-3)Actual Weight in 1m length 3.648Kg

Expected Weight in 1m length 3.503Kg

Material Waste 0.145Kg

Think About loss


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1. Changing the order of roller location Three roll mill machine.

only two rollers are using.

replace the defected roller with non used roller.

2. Roller grinding or refurbishment

cost is around Rs.85000 to Rs.145000.

3. Roller replacement with a new one

Cost is around $2000 to $5000 must imported.

4. Improvement for cutter mounting.

Only above 1 or 2 or3 solutions are not enough.

To avoid the issue permanently need to avoid direct contact of cutters and roller.

Modification is compulsory with a above solution.


F inding a most affordable solution to solve the issue


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Modif ication for M achine

New roller

Modified Design


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Project targets to measure and analysis of the calendar thickness

variation

Identified the amount of variation and the pattern of the variation

Studied and investigate the impact of the most related facts to the

issue of the thickness variation

To avoid that issue it is suggesting the following solutions

Changing the order of roller location

Roller grinding or refurbishment

Roller replacement with a new one

Modification for cutting process

Conclusion


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Calander thickness measurement and Analysis.pdf

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