Poor tool life at the Ring Plant had been a problem for many years. This issue not only affects the tool life, but the overall availability of the plant as well. Therefore, all out efforts were made in the past to improve the tool life. Even new techniques such as gas nitriding and plasma nitriding were tried but were found to be expensive and time consuming. The problem persisted for such a long time that it became not only a matter of great concern in ensuring consistency in product quality and productivity, but it was also "a sore point" with the operating personnel. Ouch, ouch! It really hurts. A proprietary "Sursulf" process hardens the tools used. The process gives rise to a hard layer of 0.3mm if nitrogen and carbon followed by a diffusion layer is around 960-1000 Vickers, which helps in achieving high tool life. After detailed investigations, it was found that the desired depth of the hard layer was not being achieved. Studies revealed that |
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 while preheating
the tool, an oxide layer was getting formed which prevented diffusion and slowed down the
rate of migration of nitrogen and carbon.
Elimination of preheating was the solution - the "samadhan" - keeping all other process parameters unchanged. This simple change increased tool life by 150%. Besides, it has made spare nitriding capacity available. Oh boy, what a solution to a problem which had almost become "an old man". With one whoosh of innovation, it has now been swept under the carpet forever. |
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Sursulf