The Problem
Water leakage in the coolant water pump of the engine.
The Challenge
Achieving a flatness of within 2 microns on the internal face of the rotary joint bush component.
Our Approach
We investigated the problem across process engineering, machine design, material analysis, and prototyping.
Our Process
The methodology included material examination of high-nickel cast iron before machining. The lapping involved positioning the component in specialized tooling with abrasives and lubrication. Precise pressure control ensured uniform material removal and flatness. Calibration adjustments were iteratively refined for micron-level precision, with real-time metrology tools, including laser interferometry and CMMs, maintaining stringent tolerances.
Our Work
We designed a highly specialized internal lapping tool that consistently maintained optimal contact, achieving a flatness target on every bush component, resulting in a remarkable 100% success rate.
The Result
Field trials with approximately 300 units over five months demonstrated success, with no reported water leakage incidents. Indian Railways and other end users expressed satisfaction with performance.