FORK BOLT TRIAL FOR FINDING SHADE VARIATION

Part name: Cap

Part no. : 13001-34090
Model : BCW

Supplier : SIGMA CNC PRODUCTS

Trial start date : 09.06.2021
Trial end date : 14.06.2021
R.M used :- A6061
Total R.M qty :- 10 Bar
Total Produced qty :- 179 Pcs

Prepared By Approved By
Manoharan R P. Elaiyaraja
Reason For Color Change in Parts

Cu%
As per our discussion with Fork Bolt
supplier
0.4%
“SIGMA CNC” and R.M Supplier “JINDAL”
the variation in color is due to variation in
copper percentage in raw material as
0.3% shown in Picture in left .

In single lot Supplier cannot control the

0.25%
variation of Chemical Composition .

On the basis of this discussion supplier has

taken a trial.
0.2%
1. Verification of % CU in lot
2. Verification of anodizing process
parameter
0.15%

RM:RM:
6061
6001

View point : Variation in Cu% causes the change in shade from light to dark
Process Flow of Trial
R.M 10 Bars R.M Marking

Red Line indicates the parting done for

Spectro from one end of the bar.

Available Total 10 bars of single cast Multiple markings done on bars to identify the parts
taken for trial easily while doing parting process

Complete Bar (No. 10 Bar)

Button Sample
Button Sample Cutting

Button sample Sent to M/S BSL (third

party ) for Spectro analysis

Parting operation Rod No. 03

Qty :- 30 Nos. /bar

Parting for Button sample to be used in

Spectro test

All Bars Parting Done & packed in same View point : 10 bars used for inspection of Spectro and trial for
manner and brought back to cold forge shade variation
Trail 1: Copper % Graph of Button Samples

0.400%
Bar no . 8, 9 having high
cu%
0.384%
0.376%

0.350% Center %
CU %

0.300%

0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275% 0.275%

0.270% 0.269% 0.272%

0.268%
0.264%
0.250%

0.234%
0.225%

0.200% 0.203%
0.193% Bar no . 3,7 having
0.183% lower cu%

0.150%
1 2 3 4 5 6 7 8 9 10A 10B 10C

Bar no.
View point : On the basis of Spectro test it is observed that difference in Cu % is 0.201
Process Flow of Trial
MACHINING CNC Turning Operation -1 Threading & grooving Operation Etching done in I.D for
done In 1St setup further Identification
OPERATION -1

MACHINING
OPERATION -2

Turning, Facing & Chamfering

CNC Turning Operation - 2 Operation done in 2nd setup

MACHINING
OPERATION -3 View point : After
Cutting each part is
engraved to avoid
the Mixing in
Hex formation done in 3rd setup Anodizing process
 ANODIZING PROCESS FLOW
SIGMA CNC PRODUCTS FORMAT NO DD/F/04
S
C
P
PQCS REV. NO 0

Key Contact
Control Plan Number ST/CP/100 Issue No. 01 Rev. 0
Phone:
Core Team:
Prototype Pre-launch Production Date (Original) 18.10.2020 Date (Revised) N/A

Part no./ Latest change no 13001-34060 Customer Engineering approval /Date if required
Part Name / Description- Cap Customer Quality Approval Date (if required)
Customer / Other Approval
Plant Supplier Code Date(if Other Approval /Date (if required)
SIGMA CNC required)
Anodizing stage
Anodizing
80.1 Anodizing 20~25µ thickness 1 1 Every Lot Insp
tester
Compare with
80.2 Color Natural 1 10 Pieces Operator 1 Every Lot Insp
master
Time-20-30
Timer 1 Each Setup Sup.
sec.
Temp. (45-
1 Etching Thermometer 1 Each Setup Sup.
50)°c

Conc.(30-60)g/l Titration 1 Each Setup Sup.

2 Water rinsing pH (7-11) pH meter 1 Each Setup Sup.

3 Water rinsing pH (7-9) pH meter 1 Each Setup Sup.

Time -20-30
Visual 1 Each Setup Sup.
sec.
4 Desmuting
Conc.(40-50)% Titration 1 Each Setup Sup.

5 Water rinsing pH (2-5) pH meter 1 Each Setup Sup.

Anodizing 6 Water rinsing pH (3-7) pH meter 1 Each Setup Sup.

80 Anodizing Rework/reject
process
time 60-70min Timer 1 Each Setup Sup.

Temp. 14-17°c Thermometer 1 Each Setup Sup.

7 Anodizing
Conc. (160-
Titration 1 Each Setup Sup.
200)g/l

Voltage 14-17V Voltameter 1 Each Setup Sup.

8 Water rinsing pH (2-5) pH meter 1 Each Setup Sup.

9 Water rinsing pH (3-6) pH meter 1 Each Setup Sup.

Time 20-25
Timer 1 Each Setup Sup.
min
10 Cold sealing
Conc.3-5 g/l Titration 1 Each Setup Sup.

11 Hot Water rains Temp. (40-50) Thermometer 1 Each Setup Sup.

Temp.(80-
Thermometer 1 Each Setup Sup.
100)°C
12 Oven
Time 8-10 min. Timer 1 Each Setup Sup.

Process flow of Anodizing process

ANODIZING PROCESS CHECKSHEET
DAILY ANODIZING CHECKSHEET DATE:- 12.06.2021

S.NO PROCESS PARAMETER SPECIFICATION METHOD FREQ.

1 2 3 4 5
Thermomete 48°
Temp. (45-50)°c 2 Shift
r
1 Etching Level 6" bellow Visual 100% OK
Conc. (30-60)g/l Titration 1/Day 58.968
Bath Cleaning By News paper Manual 1/Day OK
2 Water rinsing P.H of water (7-11) pH meter 2 Shift 10.1

3 Water rinsing P.H of water (7-9) pH meter 2 Shift 8.8

Level 6" bellow Visual 100% OK

4 Desmuting Conc. (40-50)% Titration 1/Day 45%
Bath Cleaning By News paper Manual 1/Day OK
5 Water rinsing P.H of water (2-5) pH meter 2 Shift 3.4

6 Water rinsing P.H of water (3-7) pH meter 2 Shift 4.0

Thermomete 15.6°c
Temp. Silver 14-17°c 2 Shift
r
7 Anodizing Conc. (160-200)g/l Titration 1/Day 181.3
Level 6" bellow Visual 100% OK
Bath Cleaning By News paper Manual 1/Day OK
8 Water rinsing P.H of water (2-5) pH meter 2 Shift 3.2

9 Water rinsing P.H of water (3-6) pH meter 2 Shift 3.4

Time 20-25 min Timer 2 Shift 23

Conc. 3-5 g/l Titration Daily 3.57
10 Cold sealing
Level 6" bellow Visual 100% OK
Bath Cleaning By News paper Manual 1/Day OK
11 Water rinsing P.H of water (5-7) pH meter 2 Shift 5.1
View point : Process
12 5.1
Water rinsing P.H of water (5-7) pH meter 2 Shift
parameter Verification
Thermomete
12 Hot Water Temp. (40-50°c)
r
2 Shift 40.4
sheet is verified and trail
13 Oven Temp. (80-100°c)
Thermomete
r
2 Shift 82.1 done.
Trial 2: Verification of process parameter

S
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P

SIGMA CNC PRODUCTS PROCESS VALIDATION REPORT Date:- 11.06.2021

tank Parameter Spec. Trail 1 Trail 2 Trail 3 REMARK

Process Parameter
Temp (40-50°C) temp. 45°C temp. 48°C temp. 50°C
1 Etching
Time (20-30 sec) Time 20 sec Time 20 sec Time 20 sec Pre treatment or cleaning
Conc. (40-50%) Conc. 40% Conc. 45% Conc. 50% Process
2 Desmuting
Time (20-30 sec) Time 20 sec Time 20 sec Time 20 sec
Conc. (160-200)g/l
Conc.183 gm/ltr Conc.183 gm/ltr Conc.183 gm/ltr
3 Anodizing Time (60-70 Min.) Time- 60 min Time- 65 min Time- 70 min -
Voltage(14-17 V) Volt -15 Volt -16 Volt -17
Temp (14-17°C) Temp.-16°C Temp.-14°C Temp.-13°C
Conc.-(3-5g/l) Conc.-3.58 g/l Conc.-3.58 g/l Conc.-3.58 g/l
Protective layer on the part
4 cold sealing
Time(20-25min.) Time 20 min Time 25 min Time 25 min for controlling dust & dirt

Product Parameter

colour Light Yellow

1

Anodizing thickness 19-21µ 20-22µ 22-24µ

2

Minor variation in color

shade
3 Part photo

Trailed By:- Mr.Kiran

View point : After validation it was observed that there is very minor variation in shade which is negliable
HANGER DETAIL

10 9 8 7
6 5 4 3 2 1

R9

L1

R1

L9

View point : All 10 hangers consist of all 1~9 bar parts

THICKNESS AS PER HANGER LOADING

After inspection of Top, Middle, End parts of

Hanger thickness was found OK. But variation in 3 8
shade found as the %of Cu varies in parts . Rod
No. 7 & 3 had Cu% of 0.193 & 0.183. Rod No. 8
& 9 had Cu% of 0.376 & 0.384. 7 9