Investigations on Tool Life Enhancement for Making Brake Discs of Light Motor Vehicles through the Application of Computer Aided Design and Analysis

Increasing productivity and profitability are main core objectives in the competitive manufacturing of any type of organization. Many tools and techniques are used to reduce rejections and defects of product. Most of the rejections and defects are occurred due to improper control of quality products with the use of appropriate tools. Use of ‘Seven Quality Control Tools’ is one of the best way to reduce and identifying the defects of product. Many of the defects are occurred on the brake disc. Hence it is required to reduce the same in best way. Thus a case study in an automobile manufacturing organization has been taken and defects of brake disc components has been analyzed with different materials for reducing the defects. In this investigation, the reasons for the cause of these defects are identified as the frequent changing of tool for every 50 products. It has been solved by the analyzing the tool and changing the tool material appropriately. Available modern software tools are used to analyze the tool materials. In this analysis, the tensile yield strength of the changed material has also been compared. The material changing has been done based on the material properties. The main advantage of the investigation is to increase life of the tool and hence improvement in production, productivity, and customer satisfaction.