The Analysis and Specification of Manufacturing Processes - Report Example

HЕ АNАLYSIS АND SРЕСIFIСАTIОN ОF MАNUFАСTURING РRОСЕSSЕS Name Class Instructor Institution City State Date Executive summary This is a report prepared showing different methods of producing footvalve body in port vale engineering company. it consist the best method of producing. in this case its investment casting and reasons of choosing such as its cheap and has less wastages. The process is further explained from production to assembly Contents Тhе Аnаlysis Аnd Sресifiсаtiоn Оf Mаnufасturing Рrосеssеs 1 i ТHЕ АNАLYSIS АND SРЕСIFIСАTIОN ОF MАNUFАСTURING РRОСЕSSЕS i Executive summary ii Contents 3 Possible Manufacturing Methods 4 Investment casting method 5 3-D CAD model 5 Tooling and design 6 Manufacture of internal parts 8 Costing and Pricing 9 Conclusion. 10 Introduction This report is prepared and presented by manufacturing engineer on how we can start production of valve bodies. The report shows two methods of making 30” 30 MKVII highlift footvalve. These methods are investing casting and CNC (computer numerical controlled) milling. In fort vale engineering some of methods suitable in production of foot valve are: according to (Boxall 2013) CNC milling is a method which involves a machining process like drilling or cutting done by cylindrical cutting tools that are able to make complex edges, axes, shapes or holes by use of advanced geometry. This method is mostly efficient when producing secondary parts and not axially symmetric. Investment casting it a method that uses disposable wax pattern in which it’s injected in into a liquid refractory coated mold. The mold is allowed to harden and set in shape of the pattern. It’s a method used when accuracy and high quality finish is needed. It’s a method with less tooling (Hutchinson 1982). Possible Manufacturing Methods Use of investment casting is the best method. It’s very essential to design a good valve body e.g. for water and wastewater pumping systems to satisfy intended purpose. When selecting a good method of making the body you have to take consideration of discharge check valve, this automatically open and allow forward flow and remain closed to prevent reverse flow when in operation, the thermal shock is also a important factor that is determined by production method chosen.(Patton 1980). Another function that has to be taken into consideration is ability to reduce energy used. Valves are a good method of reducing this cost so the valves should be designed in such a way there are minimal wastages (Kroon 1984). This include incorporating a valve slam which makes valve to close smoothly .Each method of producing these valve bodies is evaluated and best method chosen. Investment casting is used to produces materials of unique shapes and sizes. This method is popular in many companies due to fact that it saves time on finishing and material. Also the enable companies to combine many parts into single units and offer range of possible combination of metals and alloys. It’s a method with lowest wastages as wastages can be molded into other designs unlike drilling. I recommend this method as it can be able to produce thin walled parts and detail component for both materials are ferrous or non ferrous. This method is design flexible and has design enhancement as unlike all other methods it requires no draft (Bailun 2007). Investment casting method The following shows a process that can be used to produce a valve. 3-D CAD model A model is made to fit the metal during solidification and also it is a shape to duplicate the geometry and shape of the valve body. Specialized wax is put in the cavity to show pattern as shown in picture below. The desired pattern is then coated with slurries so that it can be able to accept molten metal. The ceramic is fired forming a solid shell leaving the cavity in which metal is poured with presence of turbo charger compressor to bring about curves and unique structures (Gifford 2004). Tooling and design In investment casting a 8 holes are drilled each of 14mm on a 200 mm pitch circle diameter forming the inlet connection to pipes also called flange to be put inside the tank as shown in figure B. Then another outlet flange which is 4 holes drilled 17mm on a 160 pitch circle diameter as shown in figure A. These all are made from 316 stainless steel which is more durable and not corrosive as shown below is a inlet and outlet flange (Babcock 1997). Depending on type of tank these can be designed in such a way it can be fitted from 45-180 degrees depending on position on the tank to be located. Sample of similar design is indicated in sample design shown below Sample design figure figure B figure A Manufacture of internal parts Figure above shows parts of a valve numbered from 1-15 as shown in table 1 the parts are also assembled in the order they follow and are produced using stainless steel. The products can be manufactured manually, bought or a machine to produce them acquired. In this study I have limited myself to the parts bought and have to meet specification in which are made of stainless steel (Schweitzer 1984). To ensure that the product is the best the following test will be done: They will be installed in pretested pressure of more than 6psg and vacuumed. The tanks will support equipment such as coils pumps and ladders. They buried more than 7 ft under. In this test shows the maximum temperature, heat and pressure the valves can be able to operate (Bosserman 1197). Costing and Pricing Item no. Description Cost in dollars 1 Body weld assembly 20 2 Forty O Ring 10 3 Solid poppet 50 4 Spring 10 5 Spring top plate 5 6 PTFE crankshaft end bush 10 7 Crank block assembly (30°) 10 8 Spindle 20 9 Viton O ring 12 10 Stuffing clamp 11 11 M6 x 20mm caps crew (3) 12 12 Handle retaining washer 10 13 Handle retaining screw 5 14 Handle 12 15 PTFE O ring (2) 3 Labor 6 Overhead expenses 14 total 220 10% mark up 22 Total cost 242 Estimated selling price 260 Profit per unit 18 Table 1 The table above shows the cost projected to be incurred in production ogf one unit of foot valve and assumed mark up of 10% on cost (.IEAT 2013). Conclusion. Casting method is cheaper and produces a lasting product which is more lasting good specification and makes more profit. Casting method will also be able to be incorporated in processes already in the organization as there are similar machines needed. This is the best method also in regard to its advantages. REFERENCES Ballun, John V., (2007). A Methodology for Predicting Check Valve Slam, Journal AWWA, March 2007, 60-65. Babcock & Wilcox, Steam, Its Generation and Use, Babcock & Wilcox Co., 1978. Bosserman, Bayard E. “Control of Hydraulic Transients”, Pumping Station Design, Butterworth-Heinemann, 2nd ed., 1998, Sanks, Robert L. ed. , pp. 153-171. Gifford, H. (2004, January). Choosing Thermostatic Radiator Valves. www.ABMA.com. Hutchinson, J.W., ISA Handbook of Control Valves, 2nd ed., Instrument Society of America, 1976, pp. 165-179.Heat Transfer, Thermodynamics and Fluid Flow Fundamentals, Columbia, MD, GeneralPhysics Corporation, Library of Congress Card #A 326517, 1982. Kroon, Joseph R., et. al., “Water Hammer: Causes and Effects”, AWWA Journal, November, 1984, pp. 39-45. Patton, James L. and Michael B. Horsley, “Curbing the Distribution Energy Appetite,” Journal AWWA, Vol. 72, No. 6., June, 1980, pp 314-320 Schweitzer, Philip A., Handbook of Valves, Industrial Press Inc. Stewart, Harry L., Pneumatics & Hydraulics, Theodore Audel & Company, 1984. INSTITUTION OF ENGINEERING AND TECHNOLOGY. (2006). Engineering & technology. Stevenage, Herts, UK, Institution of Engineering and Technology. http://www.ietdl.org/ET. BOXALL, J. (2013). Arduino workshop: a hands-on introduction with 65 projects. Read More