A NEW TECHNIQUE - NEAR MINIMUM MATERIAL ZONE, TO REDUCE THE WEIGHT OF THE COMPONENTS IN MACHINING

Ganesh Kumar N, Selvaraj P, Radhakrishnan P

Abstract: Customers buy a product when the quality of the product is high. So manufacturers produce their components to high quality. The product such as aircraft, automobile, motorcycle, etc. not only need to be produced at high quality but also at reduced weight. This is because these products performance is depend on weight of the product. A component could consist of several components. So all relevant component weights are reduced, then the overall weight of the component could be reduced. This paper introduces as new technique called "near minimum material zone" where not only the weight of the component could be reduced but also helps to increase the quality. To demonstrate this technique, two sets of experiments with 20 samples were conducted using Deckel Maho CTX310 ECO VI CNC machine. The first experiment was conducted under normal machining condition. The second experiment was conducted under this new technique. Several tools such as process capability analysis (Cp, Cpk), cause and effect diagram, X Hi/Lo and R-charts were used to analyze the case study data. The paper outcome suggests that this new technique not only helped to control the weight of the components but also improved the desired quality by minimizing the dispersion of the component dimensions to obtain higher sigma level.

Keywords: ear Minimum Material Zone, Process Capability, Cpk, Cause and Effect diagram, X Hi/Lo chart, R chart, Quality.

DOI: https://doi.org/10.15623/ijret.2013.0211092