Scribd
Upload
112 views10 pages

Experimental Inventigation On Hot Dip Galvanizion Process

This document describes a design of experiments study conducted to reduce variability in coating thickness in a hot dip galvanizing process. The study identified factors like temperature, immersion duration, and material thickness that influence coating thickness. Experiments were conducted to analyze their effects. Immersion duration was found to have the most significant impact on coating thickness. Controlling immersion duration can reduce excess zinc consumption and increase the probability of coatings being within specification limits. The conclusions provide recommendations to control immersion duration and reduce zinc deposition rate to optimize the process while minimizing zinc usage.

Uploaded by

Ranjith K
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
112 views10 pages

Experimental Inventigation On Hot Dip Galvanizion Process

This document describes a design of experiments study conducted to reduce variability in coating thickness in a hot dip galvanizing process. The study identified factors like temperature, immersion duration, and material thickness that influence coating thickness. Experiments were conducted to analyze their effects. Immersion duration was found to have the most significant impact on coating thickness. Controlling immersion duration can reduce excess zinc consumption and increase the probability of coatings being within specification limits. The conclusions provide recommendations to control immersion duration and reduce zinc deposition rate to optimize the process while minimizing zinc usage.

Uploaded by

Ranjith K
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 10

LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.

R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

DESIGN OF EXPERIMENTS STUDY IN HOT DIP GALVANIZING


PROCESS

A PROJECT REPORT

Submitted By Submitted To
RanjithKumar.K, Mr.John Christo Dinesh
QHSE-Coordinator, Managing Director
Ladco Galvanizers Private Limited, Ladco Galvanizers Pvt Ltd.
Date: 27.02.2018
LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Introduction:-

Galvanization (or galvanizing as it is most commonly called in the industry) is the


process of applying a protective zinc coating to steel or iron, to prevent rusting.
In Galvanizing process a zinc coating on iron and steel products is done by immersion of the
material in a bath of molten zinc.
Because the material is immersed in molten zinc, the zinc flows into recesses and other
areas difficult to access, coating all areas of complex shapes thoroughly for corrosion
protection.
Hot dip galvanizing provides barrier protection of the ferrous metals against corrosive
media, resistance to mechanical damage. Galvanizing provides Cathodic protection for
metal.
In Hot Dip galvanizing one of the most important quality characteristics is Coating
Thickness. In Galvanizing Process the thickness of the coating is provided according to the
customer Requirements. In some products coating thickness is higher than the requirements
More coating thickness consumes excess zinc. The objective is to reduce variability in the
production by “Design of Experimental study”.
In this Design of Experimental study “DMAIC” Framework is used.

D - Define
M - Measure
A - Analyze
I - Improve
C - Control
LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Define Phase:-

In the Hot Dip Galvanizing Process the Coating Thickness of the Hot Dip Galvanizing
process is very higher than the customer requirement, due to this Raw Material (Zinc) is
consumed excessively. “The Objective of the project is reducing the variability in the HDG
process by finding best operating condition that consumes fewer raw materials only, by
Using “DMAIC” Define, Measure, Analyze, Improve and Control framework”.

Tool Used in the Define phase:-

Cause and Effect Diagram:-

“By Brain storming technique the below attached Cause & Effect Diagram is constructed”.

The Above mentioned Factors are the influence the Output Coating Thickness
Here some of the noise Factor also available i.e (The factors can’t be controlled during
process but it can be controlled for the purpose of experiment).
Factor D,E,F are the Noise signal.
LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Measure phase:-

Critical quality characteristic of the Galvanized material i.e. Coating thickness on the
material surface processed by “Hot Dip Galvanizing” has been identified.

Randomly 40 Samples Choosen from JAK Customer Material and observations are tabulated
above.
LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Analyze phase:-

In analyze phase we use process Capability &Control charts techniques are used to
Measuer the Process capability and process variance.they are given below

“The above data clearly states that, probability 66% of materials only consumes proper
Zinc, reamining 34% of material consumes excess Zinc”.

“Standard Decviation of the process is too high”.


LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Improve phase:-

In this improve stage we shoud find best oprating condition i.e Consumes less Zinc
We should find out which factor is highly influenced on the output.
Design of excperimental techniques is used to find out the Highly influenced factor.

Factorial experiment are choosen to findout the Highly Influenced factor:-

Number of factor = 3
Number of Level = 2
Number Of Runs = 16
Number of replicates = 2

Factor Name Factor Letter Low Setting High Setting

Temperature A 445 455


Immersion Duration B 2 4
Material Thickness C 3 5

The Experimets are conducted in below mention order and results are Tabulated below:-

Green Highlighted Cells are results of Our 16 Experiments


LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

The adavantage of the full factorial experiment is an experiment whose design consists of
two or more factors, each with discrete possible values or "levels", and whose experimental
units takes on all possible combinations of these levels across all such factors.

Magnitude of the effect of the factors on output is Given below:-

From above table Factor C, factor B have a most effect on the output.

The relationship between factors and Response are Given below:-


LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

From above graph there is no interaction between any factor.


1) Immersion duration is directly proportional to Output.
2) Temperature is directly proportional to Output.
3) Material thickness is directly proportional to Output.

By ANOVA (Analysis On Variable) the Regression Model of the experiment is


Generated and given below:-

F-test for testing significance of regression is used to test the significance of the
regression model. A significant F value indicates a linear relationship between
Response and the Inputs.
From above statement,
The factor B and C have most significant effect on Output.

By controlling the Factor B, C we can obtain the required Result.


LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Results:-

Factor A effect in Negligible, C is fixed as a constant,


By varying the factor B alone the Outputs are observed from 40 samples from
“Jak Industries” Material GP29059003 and Results are interpreted below.

By varying factor A alone we can bring our Probability of producing within Specification
Limits as 96%.
LADCO GALVANIZERS PRIVATE LIMITED, CHENNAI.
R-17, SIPCOT Industrial Estate, Gummidipoondi,Thiruvallur-601201

Conclusion:-

➢ Immersion Duration is the major factor, which leads to consume Excess Zinc, By
Controlling immersion duration we can reduce Zinc Consumption.
➢ In some of the material within 2 minutes, the coating Thickness Reaches 120 Microns,
So by going through new type of flux which reduces the Deposition Rate, we can
reduce Zinc Consumption.
➢ Also by adding some additives metal along with zinc we can reduce zinc consumption.

You might also like