Scribd
Upload
1K views

Process Validation Record

The document details the process validation records for hardening and tempering of various grades of steel. It records furnace numbers, temperatures, soak times, quenching parameters, and observed hardness values for different trials. The aim was to determine the optimal hardening and tempering conditions to achieve the required hardness values for each steel grade. Various parameters were varied and their effect on hardness was noted. The conclusion lists the determined optimal hardening and tempering temperature ranges and other conditions for each steel grade to consistently obtain the required hardness.

Uploaded by

thindmanmohan
Copyright
© © All Rights Reserved
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
1K views

Process Validation Record

The document details the process validation records for hardening and tempering of various grades of steel. It records furnace numbers, temperatures, soak times, quenching parameters, and observed hardness values for different trials. The aim was to determine the optimal hardening and tempering conditions to achieve the required hardness values for each steel grade. Various parameters were varied and their effect on hardness was noted. The conclusion lists the determined optimal hardening and tempering temperature ranges and other conditions for each steel grade to consistently obtain the required hardness.

Uploaded by

thindmanmohan
Copyright
© © All Rights Reserved
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
You are on page 1/ 11

Eastman

Cast & Forge Limited

DOC NO. FMT/PROD/04

Process Validation Record (Hardening)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Date

R.M.Grade

Furnace No.

Hardening
Temp.

Soaking Time

Quenching
water temp.

Carbon
Flow
(Ltr/Hr)

Concentration
of quenching
media(%age)

Hardness
Reqd.
(HRC)

10.03.16

EN8D[ Tommy bar


no. 3, Wheel
Spanner 27 X 30
Extra Length,
Tommy bar No. 5,
Tommy bar all
sizes drive square]

GCF-1

8500C

180 Min

40

0.20

2.50

50-55

Not Ok

GCF-1

8600C

180 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8800C

180 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8900C

180 Min

40

0.20

2.50

50-55

Part not ok

GCF-1

8700C

160 Min

40

0.20

2.50

50-55

Part Not Ok

GCF-1

8700C

180 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8700C

200 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8700C

210 Min

40

0.20

2.50

50-55

Part Not Ok

GCF-1

8700C

180 Min

20

0.20

2.50

50-55

Part Ok

GCF-1

8700C

180 Min

30

0.20

2.50

50-55

Part Ok

GCF-1

8700C

180 Min

45

0.20

2.50

50-55

Part Ok

GCF-1

8700C

180 Min

50

0.20

2.50

50-55

Part Not Ok

GCF-1

8700C

180 Min

40

0.18

2.50

50-55

Part Not Ok

GCF-1

8700C

180 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8700C

180 Min

40

0.23

2.50

50-55

Part not Ok

GCF-1

8700C

180 Min

40

0.30

2.50

50-55

Part Not Ok

GCF-1

8700C

180 Min

40

0.20

2.45

50-55

Part Not Ok

GCF-1

8700C

180 Min

40

0.20

2.50

50-55

Part Ok

GCF-1

8700C

180 Min

40

0.20

3.00

50-55

Part Ok

GCF-1

8700C
860C 880C

180 Min

40

0.20

3.15

50-55

Part Not Ok

180-200 Min

Max 45

0.2

2.5-3.0

Conclusion

GCF-1

Reviewed & Approved By :-

Hardness
Observed

Remarks

Part Ok

Eastman
Cast & Forge Limited
Date

10.03.16

11.03.16

11.03.16

R.M.Grade

EN8D( Tommy bar


no. 3)

EN8D( Wheel
Spanner 27 X 30
Extra Length &
Tommy bar No. 5)

EN8D[Tommy Bar(
all size except no. 5
& 3) drive square]

EN8D[Tommy Bar(
all size except no. 5
& 3) drive square]

Hardness
required
(HRC)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Soaking
Time(Min)

Temp-1

5200C

90

Part Not Ok

Temp-1

5300C

90

Part Ok

Temp-1

5800C

90

Part Ok

5900C

90

Part Not Ok

560 C

80

Part Not Ok

Temp-1

560 C

90

Part Ok

Temp-1

560 C

100

Part Ok

Temp-1

560 C

110

Part Not Ok

Temp-1

530 C

90

Part Not Ok

Temp-1

5400C

90

Part Ok

Temp-1

6400C

90

Part Ok

6500C

90

Part Not Ok

600 C

80

Part Not Ok

Temp-1

600 C

90

Part Ok

Temp-1

600 C

100

Part Ok

Temp-1

600 C

110

Part Not Ok

Temp-1

440 C

90

Part Not Ok

Temp-1

4500C

90

Part Ok

Temp-1

5500C

90

Part Ok

5600C

90

Part Not Ok

500 C

80

Part Not Ok

Temp-1

500 C

90

Part Ok

Temp-1

500 C

100

Part Ok

Temp-1

500 C

110

Part Not Ok

30-36

530C 580C

90-100

Part Ok

25-32

540C 640C

90-100

Part Ok

35-45

450C 550C

90-100

Part Ok

Temp-1
Temp-1

Temp-1
Temp-1

Temp-1
Temp-1

30-36

0
0
0
0
0

25-32

0
0
0
0
0

35-45

0
0
0
0

Temp-1

Reviewed & Approved By :-

Hardness
observed

DOC NO. FMT/PROD/04/A

Tempering
Temp.

Furnace No.

EN8D( Tommy bar


no. 3)
EN8D( Wheel
Spanner 27 X 30
Extra Length &
Conclusion Tommy bar No. 5)

Process Validation Record


(Tempering)

Remarks

Eastman
Cast & Forge Limited

DOC NO. FMT/PROD/04

Process Validation Record (Hardening)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Date

R.M.Grade

Furnace No.

Hardening
Temp.

Soaking Time

Quenching
water temp.

Carbon
Flow
(Ltr/Hr)

Concentration
of quenching
media(%age)

Hardness
Reqd.
(HRC)

11.03.16

EN18( Wheel Spanner30X32 M&M,30x32


TELCO, 27A/F TELCO,
29 A/F TELCO, 32 A/F
TELCO, 27 A/F L&T,
30X32 EICHER, 32 A/F,
30x32 EICHER EXTRA
LONG, 15/16X1^1/8,
LONG SOCKET W/S
TYRE LEVER, SMALL
SOCKET 1^1/8)

GCF-1

8100C

45 Min

40

0.50

19.00

40-50

Not Ok

GCF-1

8200C

45 Min

40

0.50

19.00

40-50

Part Ok

GCF-1

8400C

45 Min

40

0.50

19.00

40-50

Part Ok

GCF-1

8500C

45 Min

40

0.50

19.00

40-50

Crack observed

GCF-1

8300C

40 Min

40

0.50

19.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

40

0.50

19.00

40-50

Part Ok

GCF-1

8300C

50 Min

40

0.50

19.00

40-50

Part Ok

GCF-1

8300C

55 Min

40

0.50

19.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

20

0.50

19.00

40-50

Part Ok

GCF-1

8300C

45 Min

30

0.50

19.00

40-50

Part Ok

GCF-1

8300C

45 Min

45

0.50

19.00

40-50

Part Ok

GCF-1

8300C

45 Min

50

0.50

19.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

40

0.45

19.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

40

0.50

19.00

40-50

Part Ok

GCF-1

8300C

45 Min

40

0.52

19.00

40-50

Part not Ok

GCF-1

8300C

45 Min

40

0.55

19.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

40

0.50

17.00

40-50

Part Not Ok

GCF-1

8300C

45 Min

40

0.50

18.00

40-50

Part Ok

GCF-1

8300C

45 Min

40

0.50

20.00

40-50

Part Ok

GCF-1

8300C
820C 840C

45 Min

40

0.50

21.00

40-50

Part Not Ok

45-50 Min

Max 45

0.5

18-20

Part Ok

Conclusion

EN18

GCF-1

Hardness
Observed

Remarks

Reviewed & Approved By :-

Eastman
Cast & Forge Limited
Date

12.03.16

12.03.16

12.03.16

14.03.16

14.03.16

R.M.Grade

EN18(Wheel Spanner- 30X32


M&M,30x32 TELCO, 27A/F
TELCO, 29 A/F TELCO, 32 A/F
TELCO, 27 A/F L&T)

EN18( WHEEL SPANNER- 30X32


EICHER, 32 A/F, 30x32 EICHER
EXTRA LONG, )

EN18( WHEEL SPANNER15/16X1^1/8)

EN18(LONG SOCKET W/S TYRE


LEVER)

EN18(SMALL SOCKET 1^1/8)

Process Validation Record (Tempering)


Hardness
required
(HRC)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Tempering
Temp.

Soaking
Time(Min)

Temp-1

5400C

90

Part not ok

Temp-1

5500C

90

Part Ok

Temp-1

6500C

90

Part Ok

Temp-1

6600C

90

Part not ok

Furnace No.

Temp-1

25-32

Hardness
observed

DOC NO. FMT/PROD/04/A

Remarks

6000C

80

Part not ok

Temp-1

6000C

90

Part Ok

Temp-1

6000C

100

Part Ok

Temp-1

600 C

110

Part not ok

Temp-1

4000C

90

Part not ok

Temp-1

4100C

90

Part Ok

Temp-1

5100C

90

Part Ok

Temp-1

5300C

90

Part not ok

4600C

80

Part not ok

Temp-1

4600C

90

Part Ok

Temp-1

4600C

100

Part Ok

Temp-1

4600C

110

Part not ok

Temp-1

4600C

90

Part not ok

Temp-1

4800C

90

Part Ok

Temp-1

5600C

90

Part Ok

Temp-1

5700C

90

Part not ok

Temp-1

Temp-1

35-45

32-38

5000C

80

Part not ok

Temp-1

5000C

90

Part Ok

Temp-1

500 C

100

Part Ok

Temp-1

5000C

110

Part not ok

Temp-1

5000C

90

Part not ok

Temp-1

5100C

90

Part Ok

Temp-1

5600C

90

Part Ok

Temp-1

5700C

90

Part not ok

5300C

80

Part not ok

Temp-1

5300C

90

Part Ok

Temp-1

5300C

100

Part Ok

Temp-1

5300C

110

Part not ok

Temp-1

4700C

90

Part not ok

Temp-1

4800C

90

Part Ok

Temp-1

5400C

90

Part Ok

Temp-1

5500C

90

Part not ok

5200C

80

Part not ok
Part Ok

Temp-1

Temp-1

32-38

32-36

Temp-1

520 C

90

Temp-1

5200C

100

Part Ok

Temp-1

5200C

110

Part not ok

25-32

550C - 650C

90-100

Part Ok

35-45

410C - 510C

90-100

Part Ok

EN18( WHEEL SPANNER15/16X1^1/8)

32-38

480C - 560C

90-100

Part Ok

EN18(LONG SOCKET W/S TYRE


LEVER)

32-38

510C - 560C

90-100

Part Ok

EN18(SMALL SOCKET 1^1/8)

32-36

480C - 540C

90-100

Part Ok

EN18(Wheel Spanner- 30X32


M&M,30x32 TELCO, 27A/F
TELCO, 29 A/F TELCO, 32 A/F
TELCO, 27 A/F L&T)
EN18( WHEEL SPANNER- 30X32
EICHER, 32 A/F, 30x32 EICHER
Conclusion EXTRA LONG, )

Temp-1

Reviewed & Approved By :-

Eastman
Cast & Forge Limited

DOC NO. FMT/PROD/04

Process Validation Record (Hardening)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Date

R.M.Grade

Furnace No.

Hardening
Temp.

Soaking Time

Quenching
water temp.

Carbon
Flow
(Ltr/Hr)

Concentration
of quenching
media(%age)

Hardness
Reqd.
(HRC)

15.03.16

EN18(Tyre Lever)

GCF-1

8500C

45 Min

40

0.50

21.00

58-60

Not Ok

GCF-1

8600C

45 Min

40

0.50

21.00

58-60

Part Ok

GCF-1

8800C

45 Min

40

0.50

21.00

58-60

Part Ok

GCF-1

8900C

45 Min

40

0.50

21.00

58-60

Crack observed

GCF-1

8700C

40 Min

40

0.50

21.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

40

0.50

21.00

58-60

Part Ok

GCF-1

8700C

50 Min

40

0.50

21.00

58-60

Part Ok

GCF-1

8700C

55 Min

40

0.50

21.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

20

0.50

21.00

58-60

Part Ok

GCF-1

8700C

45 Min

30

0.50

21.00

58-60

Part Ok

GCF-1

8700C

45 Min

45

0.50

21.00

58-60

Part Ok

GCF-1

8700C

45 Min

50

0.50

21.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

40

0.45

21.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

40

0.50

21.00

58-60

Part Ok

GCF-1

8700C

45 Min

40

0.52

21.00

58-60

Part not Ok

GCF-1

8700C

45 Min

40

0.55

21.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

40

0.50

19.00

58-60

Part Not Ok

GCF-1

8700C

45 Min

40

0.50

20.00

58-60

Part Ok

GCF-1

8700C

45 Min

40

0.50

22.00

58-60

Part Ok

GCF-1

8700C
860C 880C

45 Min

40

0.50

23.00

58-60

Part Not Ok

45-50 Min

Max 45

0.5

20-22

Part Ok

Conclusion EN18(Tyre Lever)

GCF-1

Hardness
Observed

Remarks

Reviewed & Approved By :-

Eastman
Cast & Forge Limited
Date

15.03.16

R.M.Grade

EN18(Tyre Lever)

Conclusion EN18(Tyre Lever)

Process Validation Record (Painting)


Hardness
required
(HRC)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Tempering
Temp.

Soaking
Time(Min)

Temp-1

5500C

150

Part not ok

Temp-1

5600C

150

Part Ok

Temp-1

5800C

150

Part Ok

Temp-1

6000C

150

Part not ok

5700C

140

Part not ok

Temp-1

570 C

150

Part Ok

Temp-1

5700C

160

Part Ok

Temp-1

5700C

180

Part not ok

560C - 580C

150-160

Part Ok

Furnace No.

Temp-1

Temp-1

32-38

32-38

Reviewed & Approved By :-

Hardness
observed

DOC NO. FMT/PROD/06/A

Remarks

Eastman
Cast & Forge Limited

DOC NO. FMT/PROD/04

Process Validation Record (Hardening)

ISSUE NO. 02
ISSUE DATE. 10.03.16

Date

R.M.Grade

Furnace No.

Hardening
Temp.

Soaking Time

Quenching
water temp.

Carbon
Flow
(Ltr/Hr)

Concentration
of quenching
media(%age)

Hardness
Reqd.
(HRC)

16.03.16

CHROME
VANADIUM( WHEEL
SPANNER- 24X27 &
19X24
L TYPE SPANNER
(ALL SIZES))

GCF-1

8500C

45 Min

40

0.20

2.50

45-50

Not Ok

GCF-1

8600C

45 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8800C

45 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8900C

45 Min

40

0.20

2.50

45-50

Crack observed

GCF-1

8700C

40 Min

40

0.20

2.50

45-50

Part Not Ok

GCF-1

8700C

45 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8700C

50 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8700C

55 Min

40

0.20

2.50

45-50

Part Not Ok

GCF-1

8700C

45 Min

20

0.20

2.50

45-50

Part Ok

GCF-1

8700C

45 Min

30

0.20

2.50

45-50

Part Ok

GCF-1

8700C

45 Min

45

0.20

2.50

45-50

Part Ok

GCF-1

8700C

45 Min

50

0.20

2.50

45-50

Part Not Ok

GCF-1

8700C

45 Min

40

0.18

2.50

45-50

Part Not Ok

GCF-1

8700C

45 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8700C

45 Min

40

0.23

2.50

45-50

Part not Ok

GCF-1

8700C

45 Min

40

0.30

2.50

45-50

Part Not Ok

GCF-1

8700C

45 Min

40

0.20

2.45

45-50

Part Not Ok

GCF-1

8700C

45 Min

40

0.20

2.50

45-50

Part Ok

GCF-1

8700C

45 Min

40

0.20

3.00

45-50

Part Ok

GCF-1

8700C
860C 880C

45 Min

40

0.20

3.15

45-50

Part Not Ok

45-50 Min

Max 45

0.2

2.5-3%

Part Ok

Conclusion

CRV

GCF-1

Hardness
Observed

Remarks

Reviewed & Approved By :-

Eastman
Cast & Forge Limited

DOC NO. FMT/PROD/04/A

Process Validation Record (Painting)


Air pressure

painting
distance

Paint mass

Gun angle

Thickness
Observed

Remarks

212

250

150

15

18

not ok

212

275

300

20

34

ok

212

300

400

30

22

not ok

250

250

300

30

32

ok

250

275

400

15

36

ok

250

300

150

20

21

Not OK

310

250

400

20

35

ok

310

275

150

30

32

ok

310

300

300

15

23

not ok

Date

Product

Paint Booth
No.

30-35 micron

5
6

Required
Thickness

ISSUE NO. 02
ISSUE DATE. 10.03.16

lower Bottom link (M&M)

Conculation: Air pressure : 212-250, Painting Distance :- 250-275, paint mass:- no effect, Gun angle :- 15-20 degree.
Reviewed & Approved By :-

You might also like