20132015 Manufacturing review Emilien Rigutto 190615 1 Summary Emilien Rigutto 190615 2 1 J3010290 Drum and internal parts prototype 1 2 J3014388 Vacuum tank 3 J3021655 ID: 392739
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Slide1
NEW FAST WIRE SCANNER 2013-2015Manufacturing review
Emilien Rigutto - 19.06.15
1Slide2
SummaryEmilien Rigutto - 19.06.152
1. J3010290 Drum and
internal
parts prototype 1
2. J3014388 Vacuum tank
3. J3021655
Drum and internal parts prototype 24. ConclusionSlide3
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0011 x1
Subcontracting to POLMANS (BE), CA5311295, 2721 CHF, report 1297365,
no
conformities
detected
.SPSBWSRE0010 / 0008 x1+1 Raw
m
aterial purchase INCONEL : 640 CHF.SPSBWSRE0021 x1
Emilien Rigutto - 19.06.15
3Slide4
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0011 x1
Subcontracting to POLMANS (BE), CA5311295, 2721 CHF, report 1297365,
no
conformities
detected
.SPSBWSRE0010 / 0008 x1+1 Raw
m
aterial purchase INCONEL : 640 CHF.SPSBWSRE0021 x1
Emilien Rigutto - 19.06.15
4Slide5
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0014 x2
Roughing the 2 parts
Relieving
heat
treatmentFinal machining, turning of
thin
paroies (0.3mm) with specific internal mandrel
(new
request from
Dmitry
: 0.2mm)
EtchingElectron
beam welding
Leak
test
Emilien Rigutto - 19.06.15
5Slide6
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
6Slide7
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
7Slide8
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
8Slide9
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
9Slide10
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
10Slide11
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
11Slide12
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
12Slide13
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Roughing POS 2 / 3 / 6Rolling, welding
,
calibration POS 4
Heat
treatment POS 2 / 3 / 4 / 6Finishing POS 6, semi finishing
POS 2
EB
welding POS 2 et 6Finishing POS 2Roughing POS 4EB welding
POS 2 et 4Semi f
inishing POS 4
Roughing POS 3EB
welding POS 3 et 4Finishing
with «
cradles»Welding
of POS 1 / 5 / 6
Emilien Rigutto - 19.06.15
13
Manufacturing
process
proto 1 :
39
Steps
(
turning
,
milling
,
forming
,
heat
treatment
, EB
welding
,
wire
cutting
,
cleaning
,
control,
leak
test…)
Metrological
report
(
edms
1357632) :
- Default of
coaxiality
0.025 and 0.03
between
Ø 32 and 47 H7
Difficulties
:
Deformation
POS 3
Concentricity
of Ø H7
Final
machining
with
«
cradles
»Slide14
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Emilien Rigutto - 19.06.15
14Slide15
1. J3010290 Drum and internal parts, proto 1, 2013-2014SPSBWSRE0005 x1
Emilien Rigutto - 19.06.15
15Slide16
1. J3010290 Drum and internal parts, proto 1, 2013-2014Emilien Rigutto - 19.06.15
16
Cost
analysis
:
Stainless steel 316LN 3D
forged
purchase for POS 2, EDH 5295236 (with 2 spares) = 8.885 CHF (2.980 CHF / drum
)Raw
material purchase, EDH 5294041 (
with 4 spares
for the flange DN400) = 18.221 CHF (
7.780 CHF /
drum)Subcontrating
shaft
SPSBWSRE0011
, CA5311295,
2.721 CHF
Purchase
Inconel,
640 CHF
Mechanical
operations
(
including tooling
) : 30.225 CHFWelding
and forming
operations
:
3.120 CHF
Metrology
operations
:
2.080 CHF
EB
welding
operations
:
2.000 CHF
Heat
treatment
:
1.000 CHF
Total Job: 51.915 CHF
(
cleaning
not
including
)
Total
only
drum
:
41.905
CHFSlide17
2. J3014388 Vacuum tank, 2014Emilien Rigutto - 19.06.1517
Manufacturing
of 2 tanks SPSBWSRE0002
Standard
tolerances
(
be careful
coaxiality
Ø190H7 : 0.4mm)
Manufacturing process : 45 stepsSpinning POS 8, OLSEN, CA5490086Metrological report edms 1381812, OK
Cost
analysis (pour 1 tank) :
Material purchase : 6.737 CHF
Mechanical operations :
9.750 CHFForming and welding
operations : 5.525 CHF
EB
welding
operations
:
780 CHF
Subcontracting
of
spinning
:
1.930 CHF
TOTAL : 24.722 CHFSlide18
3. J3021655 Drum and internal parts, proto 2, 2014-2015Emilien Rigutto - 19.06.15
18
Different
approach
for the
drum: - subcontracting a maximum mechanical operations for a mass production of 20 to 25 drums
Creating
intermediate drawingsPrice inquiryCA5847257 Rottger’s (DK)
Metrological
report
edms
1473488 : OKSlide19
3. J3021655 Drum and internal parts, proto 2, 2014-2015Emilien Rigutto - 19.06.15
19
New
manufacturing
process
, shorter, 24 steps.
Costs
analysis for the drum PROTO 2:Material
purchase: 9.000 CHF
Mechanical subcontracting
: 8.526 CHFForming
and welding operations
: 3.380 CHFMechanical
operations:
12.350 CHF
EB
welding
operations
:
2.000 CHF
Heat
treatment
:
1.000 CHF
TOTAL : 36.256
CHF
Costs
analysis
for the
drum
PROTO 1:
Material
purchase
:
10.760
CHF
Mechanical
subcontracting
:
NO
Forming
and
welding
operations
:
3.120
CHF
Mechanical
operations
:
25.025
CHF
EB
welding
operations
:
2.000 CHF
Heat
treatment
:
1.000 CHF
TOTAL :
41.905 CHF
Why
differences
:
Existing
tools
Experience
of the prototype 1Slide20
4. ConclusionEmilien Rigutto - 19.06.1520
Internal
parts :
Internal
manufacturing : possibleSubcontracting : already done, for a production of 25 units,
we
can estimate a discount of 30%. Vacuum tank : Internal
manufacturing : already done
Subcontracting : possible, be
careful to the tolerances and EB
welding, we can
estimate a discount of 30%.
- Drum
:
Mechanical
roughing
with
subcontracting
is
validated.
We recommend
finishing in the main worshop
because EB welding and critical
operations
Adding
calibration
procedures
Study
of a new
clamping
system for the final
milling
operation
(
removal
of
cradles
)