JAY FE CYLINDERS LIMITED

A JPM GROUP OF COMPANY

(High Pressure Gas Cylinder Plant)
Bawal Industrial Area,
District Rewari,
Haryana, INDIA
1

Outline of manufacturing process

of light weight cylinders

JAY FE CYLINDERS LIMITED

10.12.2016

Internationally recognized cylinder Manufacturing Process.

EXISTING PROCESS FLOW DIAGRAM:

PIPE
CUTTING

BOTTOM
MILLING

BOTTOM
SPINNING

NECK
TAPPING

NECK
CUTTING

HYDROSTATIC
STRECTH
TEST

AIR LEAKAGE
TEST

VALVE
ASSY

PAINTING

N2 GAS FILLING &

LEAK CHECK

NECK
SPINNING

HARDNESS
TEST

HOT WATER
CLEANING

STAMPING

BRACKET ASSEMBLY

ULTRASONIC
TEST

HEAT
TREATMENT

ISB/ESB

VACCUM
CLEANING

PRE DISPATCH INSP.

DISPATCH

PROPOSED PROCESS FLOW DIAGRAM:

PIPE
CUTTING

HEAT
TREATMENT

PAINTING

NECK
SPINNING

NECK
CUTTING

HARDNESS
TESTING

STAMPING

BOTTOM
MILLING

BOTTOM
SPINNING

ULTRASONIC
TEST

VACCUM
CLEANING

ISB/ESB

VALVE
ASSY

EDGE
CUTTING

NECK
TAPPING

AIR LEAKAGE
TEST

N2 GAS FILLING &

LEAK CHECK

DISPATCH

SHOT
BLASTING

FLOW
FORMING

HYDROSTATIC
STRECTH
TEST

HOT WATER
CLEANING

BRACKET ASSEMBLY

PRE DISPATCH INSP.

Change point from existing to proposed.

al three process will remain same and after that 3 new operation will be added

Shot Blasting : This is a cleaning process to remove the surface scale. This proces
will be identical to our existing shot blasting process done before painting.

low Forming : This process is intended to get the uniform thickness, which will
ultimately control the weight of the final cylinder.

dge Cutting : After flow forming operation the edges will be irregular. For neck
spinning, the edges should be uniform and at right angle to parallel portion.

nspection of the cylindrical shell will be additional station, to confirm the surface
finish and other parameters.

Flow forming operation :

eduction in thickness by Rotary Flow forming machine:

w forming operation increases the length of the Cylinder (Bottom formed) while reducing the wall the w
ckness by inducing the material to flow by the pressing of forming roller on to the rotating cylinder shel

s cylinder shell is fitted on a rotating mandrel.

he machine there will be option to use a cut to length pipe or Bottom formed pipe, for both the cases s
ooling arrangement is used to send the material flowing in opposite direction.

e machine will be equipped with fixed roller housing and moving head stock and tail stock.
est German made flow forming machine design concepts employs state of art technology such as
ctromechanical drives using ball screw spindle with servo motors controlling the axial or radial machin

e innovative design machine selected will yield effective thickness reduction ratios and higher feed rate
ill also be ensured that we get excellent product and surface finish quality ; ensuring high efficiency an
ductivity by optimizing operation cycle time.

Flow Forming Machine

Flow Forming Machine in operation

Flow Forming Process - Advantages

Better accuracy, closer geometric tolerances.
Better surface finish.
Uniform wall thickness.
Hardened microstructure.
This process provides us the choice to set the grain

direction as per our choice.

Little or no residual stress.
The pressure exerted on the material increases
material stability, if material not stable, then it will
fail in the pre process itself.
No heating of work required

Disadvantages of flow Forming

Higher forces and power required, means cost investment.
Surfaces of starting work piece must be free of scale and dirt.
Ductility and strain hardening limit the amount of forming that

can be done
In some operations, metal must be annealed to allow further
deformation
In other cases, metal is simply not ductile enough to be cold
worked

Flow Forming Process - Limitations

Selected material can only be processed with this

method.
Parameter optimization need expertise.
The hardness variation in the seamless tubes should
be minimized
(5 ~ 10BHN) to avoid thickness variation and ovality.
Maintenance and upkeep of rollers a critical factor.
Though reduction in feed rate improve surface finish
but its effect is there on ovality and mean diameter.

ritical Parameters of flow forming process

- Should be homogeneous
MATERIAL

- Steel should not be made by conventional method,

the refining level should be above ESR (Electro Slag).
- Material should be free from hard spots i.e. Hardness
band across the lot should be with in 10BHN.

- Entry Angle.
ROLLER
- Radius
GEOMETRY
- Exit Angle.
- Material

ritical Parameters of flow forming process

STAGGER

- Final Geometric tolerances depends on the same.

SPEED
the

- Chances of circumferential crack, if optimised improves

surface finish.

FEED
will

- Less feed will give good surface finish but productivity

reduce and increase cost.

%REDUCTION - Non uniform deformations may cause crack, if

reduction is less.

Consumables (additional):
1.Rollers
2.Mandrels
3.Special coating on the Mandrel to avoid cold
welding.
4.Water coolant with soluble oil mixed.

WEIGHT REDUCTION

THEORTICAL

Weight Reduction

Max case

Min case

(kg/m)

JFE steel pipe

production

t (mm)

D (mm)

L (mm)

W (kg)

7.6

316

720

41.4

57.4

317 mm diameter

7.5

316

720

40.8

56.7

min. 6.5 mm

7.4

316

720

40.3

56.0

range: 6.5 8.45 mm

6.7

316

720

36.6

50.8

target thickness: 7.5 mm

6.5

316

720

35.5

49.3

kg/m=57.2 kg/m

As receive (mm)

after FF (mm)

weight reducing
(kg)

7.6

6.5

5.9

7.5

6.7

4.3

7.4

6.7

3.7

(D*D*3.14/4)-(D-2t)(D-2t)*3.14/4=3.14/4(D*D-D*D+4Dt4t*t)
=3.14/4(4Dt-4t*t)=3.14(Dt-