Transcript HARTWELL CORPORATION UC IRVINE

HARTWELL CORPORATION
UC IRVINE
MAE 188
Engineering Design Industry
Flush Handle Latch Assembly Redesign
Students
Faculty Advisors
Hartwell Corp. Engineers
Jeremy Kim
Kevin Wen
Phong Diep
Yuk Ming Wong
Derek Dunn-Rankin
Haris J. Catrakis
J. Michael McCarthy
Frank T. Jackson
John F. Gillen
Tim Rozema
Goal Statement
•
Redesign the H3414-33 flush handle latch assembly to reduce its
manufacturing cost and improve its wearability.
Flush Handle Latch Assembly H3414-33
•H3414-33 has 92 parts per assembly
•Customers
– Canadair
– Bombardier
Specifications
Metric
Marginal
Ideal
$ each for
quantity of 100
# parts
Less than current
(< $1302.46)
50% less
20% less
($1041.97)
None
Durability
Cycle/return
30,000
300,000
Functionality
Qualitative
Same
Same
External
geometry
Weight
Qualitative
Same
Same
Lbs
20% less
(5.4)
-50 to 200
50% less
(3.3)
-80 to 300
Cost
Plating usage
Temperature
range
°F
Cost
Modified Cost Auditor Quote by TMC
•
ASSEMBLY NUMBER : H3414-33
Rev :
DESCRIPTION:
Cost Analysis
Cost analysis is based on Cost Auditor
Quote with quantity of 100
Total manufacturing cost = $1,302.46
Labor cost includes overhead rate factor
of 4.03 (burdened labor)
4 categories of manufacturing cost
–
–
–
•
•
•
•
O/P
6.80%
MATL
34.07%
100 RCVD DATE :
NOTES:
Total Manufacturing Cost(TMC)
Hours
Itm
–
QTY:
Burdened Labor
Material
Outside Processing
Purchase Each
PurEa
6.99%
B Labor
52.13%
Total Manufacturing Cost Breakdown
02/05/01
4
30
35
39
101
41
46
53
32
2
21
28
74
64
12
1
90
34
8
96
91
73
25
48
76
49
24
38
81
83
19
58
23
85
15
79
59
44
43
62
98
68
66
17
PART NO.
DESCRIPTION
132797-600
handle unpainted
117063-9
housing
119922-3
actuator
117067-5
collar
H3414-33
latch assy flush handle
117068-3
release lever
118616-1
cover
MS21151-8
ABR4M-8
117065-3
inner support
103966-9
trigger
130506-5
actuator rod
132908-3
fitting
130383-1
plate
HSP226CDC1650AA spacer
119667-1
spring leaf
H3414-35
handle assy
132390-1
spring
117066-3
actuator assy
119668-3
trigger lift assy
118654-1
actuator screw
HSP221HWW730AA bushing
130331-5
link assy
132077-1
guide button
119117-1
target spring
130384-5
link
NAS1423C6
nut
107846-1
spring-dt trigger
22DU12
bearing
HSP148-9-093-680 rivet
HSP221JDC525AA bushing
HSP226CDC530AA spacer
Q4126-559N
quad ring
117069-5
spring
HSP108-4-093-320 rivet
HSP115P094-1250 pin
HSP115B094-1000 pin
Q4125-559N
quad ring ethylene
117075-3
name plate
117069-1
spring
Q4025-559N
quad ring
HSP115B062-350
pin
5710-134-30P
cres washer
HSP115P094-1865 pin
HSP115B094-900
pin
Totals for Top Assembly
QTY
TYPE
S/U
Ea. Pc
** Direct Cost **
MATL
%TMC
RATE
LABOR
B Labor
%TMC
1.00 MF 14.25 1.724 15.16
1.00 M 10.50 1.166 14.76
1.00 M
8.50 0.613 14.87
1.00 M
5.00 0.406 15.43
1.00 A
0.00 1.373 12.69
1.00 M
2.75 0.274 16.45
1.00 M
5.50 0.265 14.77
1.00 P1
1.00 M
6.50 0.420 14.81
1.00 MF 3.25 0.202 16.26
1.00 M
4.00 0.424 15.05
1.00 M
3.25 0.275 15.96
1.00 M
2.75 0.132 14.53
1.00 M
3.00 0.196 14.24
1.00 P2
1.00 MF 0.00 0.133 12.70
1.00 P2
1.00 MA 0.00 0.125 11.54
1.00 MA 0.00 0.010 9.41
1.00 M
2.00 0.060 15.25
1.00 M
2.25 0.069 13.52
1.00 MA 0.65 0.095 12.24
1.00 P2 2.50 0.043 15.23
1.00 P2 0.00 0.001 16.20
1.00 M
1.55 0.057 14.05
1.00 P1
1.00 P2
2.00 P1
2.00 M
1.50 0.031 14.30
2.00 M
1.75 0.038 14.04
1.00 M
1.00 0.039 14.19
2.00 P1
1.00 P2
4.00 M
1.00 0.027 14.31
1.00 M
1.25 0.020 12.93
1.00 M
0.75 0.026 12.96
1.00 P1
1.00 M
1.63 0.013 12.59
1.00 P2
1.00 P1
1.00 P1 0.50 0.015 13.41
1.00 P1
1.00 M
0.58 0.011 11.18
1.00 M
0.58 0.009 10.51
$28.30
$18.76
$10.38
$7.04
$17.42
$4.96
$4.73
$114.03
$75.60
$41.83
$28.36
$70.22
$19.99
$19.05
11.04%
7.32%
4.05%
2.75%
6.80%
1.94%
1.84%
$75.34
$85.75
$53.75
$41.30
7.30%
8.31%
5.21%
4.00%
$35.42
$25.65
3.43%
2.48%
$7.18
$3.81
$6.98
$4.91
$2.32
$3.22
$28.95
$15.37
$28.14
$19.78
$9.34
$12.97
2.80%
1.49%
2.73%
1.92%
0.90%
1.26%
$2.00
$17.00
$1.83
$2.55
$9.20
$0.02
0.19%
1.65%
0.18%
0.25%
0.89%
0.00%
$1.69
$6.81
0.66%
$1.44
$0.09
$1.22
$1.24
$1.24
$1.04
$0.02
$1.02
$5.81
$0.38
$4.92
$4.99
$5.01
$4.17
$0.07
$4.11
0.56%
0.04%
0.48%
0.48%
0.48%
0.40%
0.01%
0.40%
$0.24
$0.12
0.02%
0.01%
$0.10
0.01%
$0.13
0.01%
$0.66
$0.63
$0.61
$2.65
$2.55
$2.46
0.26%
0.25%
0.24%
$0.13
$0.13
$0.01
0.01%
0.01%
0.00%
$0.41
$0.42
$0.43
$1.67
$1.69
$1.75
0.16%
0.16%
0.17%
$0.14
$0.10
$0.03
0.01%
0.01%
0.00%
$0.37
$1.49
0.14%
$0.02
0.00%
$0.23
$0.92
0.09%
$0.01
0.00%
$0.19
$0.16
$0.76
$0.63
0.07%
0.06%
$0.14
$0.03
134
$133.55
$538.21
52.13%
$351.80
89.90 8.326
O/P
PurEa
Mfg Cost
0.01%
0.00%
$42.50
$7.00
$3.00
$1.50
$0.00
$1.50
$1.00
$0.00
$1.50
$0.00
$0.00
$6.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$5.00
$0.00
$0.00
$0.00
$0.00
$1.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.25
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$32.50
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$7.40
$0.00
$6.30
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$3.20
$0.00
$3.70
$3.40
$2.80
$0.00
$0.00
$0.00
$2.00
$1.90
$0.00
$0.00
$0.00
$1.70
$0.00
$1.40
$1.20
$0.00
$1.00
$0.00
$0.00
$231.87
$168.35
$98.58
$71.16
$70.22
$56.91
$45.70
$32.50
$32.44
$32.37
$29.97
$28.33
$18.54
$12.99
$7.40
$6.81
$6.30
$5.81
$5.38
$5.16
$5.11
$5.01
$4.27
$4.27
$4.23
$3.70
$3.40
$2.80
$2.78
$2.68
$2.47
$2.00
$1.90
$1.82
$1.79
$1.78
$1.70
$1.51
$1.40
$1.20
$1.18
$1.00
$0.90
$0.66
34.07%
$70.25
$72.20
$1,032.46
TOTALS
TOTAL LABOR
OVERHEAD RATE
$133.55
4.03
(x)
BURDENED LABOR
OUTSIDE PROCESSING
MATERIALS
PURCHASING
$538.21
$70.25
$351.80
$72.20
(+)
TOTAL MANUFACTURING
G & A RATE
$1,032.46
1.32
(x)
TOTAL COST
PROFIT RATE
$1,362.84
1.15
(x)
UNIT SALE PRICE
$1,567.27
$898.39
$18.54
$29.97
$28.33
$870.06
$807.73
$32.37
$775.28
$32.50
$45.70
$56.91
$32.44
$742.78
$697.08
$640.18
$70.22
31
13
03
8
83
13
29
0
65
13
05
0
69
39
6
53
70
6
10
M
S2
11
11
51
-8
61
11
11
86
1
83
70
6
14
-3
3
34
H
Labor includes Overhead Rate (Burdened Labor)
02/09/01
87.0%
84.3%
2.7%
2.9%
1.8%
81.4%
3.1%
3.1%
4.4%
3.1%
75.1%
67.5%
5.5%
10.00%
6.8%
20.00%
9.5%
30.00%
16.3%
40.00%
6.9%
50.00%
55.2%
48.3%
38.8%
60.00%
62.0%
80.00%
70.00%
71.9%
S %TMC
78.2%
%TMC
90.00%
88.8%
H3414-33 Manufacturing Cost As % Of TMC
100.00%
Quantity: 100
Labor includes Overhead Rate (Burdened Labor)
31
13
03
8
83
29
0
13
65
13
05
0
69
39
6
10
53
11
70
6
-8
11
51
M
S2
61
86
1
11
83
70
6
11
H
34
14
-3
3
75
70
6
11
23
0.00%
99
2
H3414-33 : $70.22 (6.8% TMC)
117068-3 : $56.91 (5.5% TMC)
75
11
Quantity: 100
11
•
•
70
6
23
99
2
11
11
70
6
760
0
39
$0.00
39
Redesign/replace the costly components
with less expensive alternatives
Other candidates
$71.16
$100.00
70
6
material
burdened labor
outside processing (O/P)
purchase cost of each (PurEa)
$569.96
$498.80
$400.23
$200.00
$98.58
$168.35
$231.87
$231.87
$300.00
11
–
$400.00
Individual cost analysis for these 4 parts
•
•
•
•
–
$500.00
22.5%
22.5%
–
132797-600 Handle : $231.87 (22.5% TMC)
117063-9 Housing : $168.35 (16.3% TMC)
119922-3 Actuator : $ 98.58 ( 9.5% TMC)
117067-5 Collar : $ 71.16 ( 6.9% TMC)
$600.00
27
9
•
•
•
•
$700.00
0
–
S Mfg Cost
$800.00
760
–
92 total parts
13 most expensive parts make up 88.8% of
the total manufacturing cost
4 most expensive parts make up over 55%
of the total manufacturing cost
Identify the 4 most expensive parts
27
9
–
–
Mfg Cost
$900.00
13
Approach
13
•
$840.09
H3414-33 Manufacturing Cost
$1,000.00
$916.93
Cost
02/09/01
Cost
Cost Breakdown Of 4 Most Expensive Parts
$250.00
O/P
MATL
B Labor
$42.50
$200.00
Cost ($)
$7.00
$150.00
$75.34
$85.75
$3.00
$100.00
$1.50
$53.75
$114.03
$50.00
$41.30
$75.60
$41.83
$28.36
$0.00
handle
132797-600
housing
117063-9
actuator
119922-3
Part
collar
117067-5
Wearability
Coating and paint chipping (132797-600)
Wear on handle shaft (132797-600)
Wear on inner of collar (117067-5)
Wear on inner support (117065-1)
Wearability
Wear sensitive parts
Part
Trouble
Probable Cause
Corrective Action
(110B)
(115B)
(140A)
Outside handle does not extend
to operating position when
trigger (115B) is pushed.
Damaged or improper
installation of spring trigger
(140A).
Check spring for deformation.
Replace the damaged parts.
(90)
(110B)
(315B)
Excessive torque required to turn
the outside handle assembly.
Binding between the actuator
fitting (90) and/or the housing
(315B).
Clean and check components for
uneven or excessive wear and
worm through areas in solid film
lubricant. Repair or replace
parts.
(90)
(220)
Actuator does not turn the
required angle.
Damaged or improperly installed
actuator fitting (90) or actuator
(220)
Check the components for
damage. Repair or replace parts.
(110B)
(65A)
Excessive force required to push
the outside handle assembly
(110B).
Binding between the inner
support (65A) and the rod
(165B).
Check the inner support and the
rod for damage. Replace the
damaged parts.
(80)
(160)
Outside handle does not extend
to operating position when
trigger is pushed.
Damaged springs (80 or 160).
Check spring for deformation.
Replace the damaged spring.
(65A)
(165B)
Outside handle does not extend
to operating position when
trigger is pushed.
Binding between the inner
support (65A) and the rod
(165B).
Check the inner support and the
rod for damage. Replace the
damaged parts.
(290)
Outside handle does not extend
to operating position when
trigger is pushed.
Bent pin (290)
Replace the pin.
Hartwell Corporation, Components Maintenance Manual Part Number H3414. Fault isolation.
Technical Issues
•
•
•
•
Materials
Manufacturing Process
Machining
Functional Design
Materials
Density Tensile S trength Elongation Modulus of Elasticity CTE, Linear Thermal Conductivity
Current Materials
17-4ph Stainless Steel (Handle)
7.65 g/cc
160 ksi
11%
29,000 ksi
6.1 m(ºF)-1
9.5 Btu/ft-h-°F
A356.0T61 Aluminum Alloy (Housing, Actuator and Collar)
2.7 g/cc
41 ksi
10%
10000 ksi
11.9 m(ºF)-1
87 Btu/ft-h-°F
1.45 g/cc
38 ksi
0.8%
5,207 ksi
7.9 m(ºF)-1
6.5 Btu/ft-h-°F
1.42 g/cc
32 ksi
1%
1,798 ksi
7.8 m(ºF)-1
6.4 Btu/ft-h-°F
M . A. Hanna Edgetek CTX-1110 Polyetheretherketone with Carbon Fiber
1.407 g/cc
30 ksi
2%
1,305 ksi
7.9 m(ºF)-1
6.5 Btu/ft-h-°F
M . A. Hanna Edgetek PK-30CF/000 Polyetheretherketone - 30% Carbon Fiber Reinforced
1.42 g/cc
30 ksi
1.5%
2,596 ksi
8.0 m(ºF)-1
6.5 Btu/ft-h-°F
Victrex PEEK TM 150CA30, 30% Carbon Fiber Reinforced
Victrex PEEK TM 450CA30, 30% Carbon Fiber Reinforced
1.41 g/cc
32.6 ksi
2%
1,885 ksi
6.4 Btu/ft-h-°F
1.41 g/cc
32.5 ksi
2%
1,885 ksi
7.8 m(ºF)-1
7.8 m(ºF)-1
Alternative Materials
RTP Company Grade 3887 Polyaryletherketone (PAEK) Carbon Fiber 40%
DSM Ketron
•
TM
PEEK 30% CF (Inj), Polyetheretherketone, 30% Carbon Fiber Reinforced, Injection M olded
Coatings
–
•
Housing Cavity (Except Area of Prox Switches) and Inner Surfaces of Handle are coated with Emralon 310
PTFE
Electroless Nickel Plating
–
•
6.4 Btu/ft-h-°F
Handle Assembly
Painting
–
Customer Choice
Manufacturing Processes
•
Current Processes
132796-1 (handle)
117052-999 (housing)
119922-997 (actuator)
117067-999 (collar)
•
Machining
X
X
X
X
Alternatives
–
Roll forming
•
•
–
–
Metal
Shorter manufacturing time
Injection Molding
•
Requires plastic as material
Compression Molding
•
•
Casting
X
X
X
X
Requires plastic as material
Cost of Process
–
–
Tooling cost
Raw material cost
Forging
Plating
X
Surface Finishing
X
X
X
X
Precision Inspection
X
X
X
X
Machining
•
Current Sequence
– setting fixture  setting tooling  checking programs  inserting casted parts  remove
finished parts  inspection  storage
•
Alternatives
– net-shape forming
Advantages
virtually no material waste
Mold parts into high-precision finished parts
lower manufacturing cost by saving machining
time
Ideal for complex shapes
Disadvantages
 lower energy product because material is
diluted by the binding polymer
 decreased corrosion resistance
 lack of high quality, reasonable-cost power
price for general alloys average $40/pound
–
outside processing (O/P) in foreign countries
Outside processing in foreign countries has several disadvantages:
 present currency exchange rate between Europe and America limits the benefits
 complexity of certain parts makes O/P impossible. Reliability and quality control becomes a problem.
 instability of foreign work force
–
machining optimization
 install software to provide a better integrated CNC production facility
 change tooling and carbide brand and type
 install high pressure coolant systems to increase production efficiency and extand tool life time
Functional Design
•
Technical Specifications
DESCRIPTION
Property
Manufacturer
Part Numbers
Hartwell Corporation
Canadair
Existing
–
Specifications
Hartwell Corporation (CAGE 83014)
–
H3414-9,-23,-25,-29,-33
601R38132-7, 601R38132-9, 601R38132-11,
601R38132-11, 601R38132-13
Flush Handle Latch Assembly
Nomenclature
FUNCTIONAL CHARACTERISTICS
Handle Travel
44 to 46 Degrees (counterclockwise)
Outside Handle Extension to
Operating Position
1.45 to 1.55 in. (36,83 to 39,37 mm)
Torque Required to Turn Handle
10 in-lbs (1,13 N.m) maximum at 55 to 75*F (13 to 24*C)
Force Required to Stow Outside Handle 15 lbs (6,8 kg) maximum
Pressure Difference Without Leakage 18.5 psig (123 kPag) maximum
PHYSICAL CHARACTERISTICS
Overall Dimensions
Height
8.81 in. (223,77 mm)
Width
7.57 to 7.87 in. (192,28 to 199,89 mm)
Length
15.17 to 15.28 in. (385,32 to 388,11 mm)
Weight
6.6 lbs (3,0 kg) maximum
–
–
–
–
A spring-loaded release lever that
extends and rotates the outside handle
assembly from inside the door.
A spring-loaded outside handle
assembly that seats flush in the housing
when stowed for flight, and extends
under spring load for use when the
trigger or release lever is pushed.
The flush handle latch assembly consists
of one each: release lever, rod end,
cover, actuator rod (not shown), outside
handle assembly with integral springloaded trigger, trigger lift assembly
actuator fitting, inner support, and a
collar.
Components are secured by attaching
hardware and pins retained by sealant.
Elastomer quad rings in the actuator
assembly, inner support, and collar
provide environmental and pressure
seals.
Qualification
Functional Design
• Alternatives
–
–
–
–
fewer parts
simplified assembly
new materials
new manufacturing processes
• Testing
• Wearability
Design Concepts
1.
2.
3.
4.
Materials
Manufacturing
Machining Optimizations
Functional Design
Design Concept 1
Materials
•
•
Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced instead of aluminum alloy for collar and
flush handle housing
Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced
–
Cost
•
Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced are packaged in 55.1 lb boxes
1 - 11 boxes - $ 40.75 /lb
12 - 23 boxes - $ 38.50 /lb
24 + boxes - $ 36.50 /lb
Collar
•
Advantages
–
–
–
•
Saving approximately $31 per collar ( 75 % material cost )
Saving approximately $65 per housing ( 73% material cost )
Lighter Weight
Disadvantages
–
–
–
Reducing the tensile strength in 20%
Brittleness
Temperature Range ( -85°F - 599 °F )
Flush Handle Housing
Design Concept 2
Manufacturing
•
Manufacturing Method
Casting (Current)
•
–
–
–
–
Injection Molding (Alt.)
Housing Tooling charge: $14,100.00 Tooling charge: $20,000.00
(117063-9)
Material: $85.75
Material: $20.00
Machining: $75.60
Machining: $0.00
Collar
Tooling charge: $4,500
Tooling charge: $7,000.00
(117067-5)
Material: $41.30
Material: $10.00
Machining: $28.36
Machining: $0.00
•
No machining required
No surface finish required
No plating required
Lower material cost
Disadvantages
–
Material change required
–
Investment in tooling charge
Casting vs. Injection Molfing
Change in manufacturing cost (quantity of 100 per year)
350
TMC (Alt)
–
–
next year : 85.75  20  41.30  10  75.60  28.36
 $201.01decrease
$68.99
 1.34 years 1 year 4 monthsto overcomethe
– 1
$201.01
injectionmolding toolingcharges
–
TMC (curr)
first year : 20000 7000  85.75  20  41.30  10  75.60  28.36
100
 $68.99 increase
$201.01
 15.4% decreasein T MC
$1302.46
300
250
Cost ($)
•
Advantages
200
150
100
50
0
1
2
3
Year
4
5
Design Concept 3
Machining Optimizations
Machining optimization: software
 Integrated machining system for production facility from GE Fanuc
 VisualDocs - Designed to replace paper and improve productivity on the shop floor, this software can
provide operators with access to virtually any information on the floor, helping them tap
into the combined operating knowledge of the company.
 VisualMEM - Designed to help manufacturers gather machine performance information on the floor,
VisualMEM (Machine Event Monitoring) records each event that takes place on a
machine and places that information in a database for further analysis. 10% production
improvement typical when implemented.
VisualDocs
Visual MEM
EV 2000
Machining optimization: hardware
 change tooling and insert type or brand
 For the machining of 17-4 PH stainless steel and A356.0 T61 Al alloy, two alternative
tooling inserts from Kennametal are suggested:
insert geometry:
recommended Grade:
feed rate:
depth of cut:
For 17-4 PH stainless steel
MM-MR
KC9025
0.0255 in
0.2102 in
For A356.0 T61 Al alloy
MS
KD100
0.0186 in
0.1046 in
 install EV2000 high pressure coolant system produced by chipblaster (unit price: $15,695)
 machining time and tool life time will increase 30% minimum
 cost saving study:
- 8.477 hrs of machining labor per piece under regular coolant system
- overhead rate of 4.03
- assume an average labor rate of $15.00/hr
- assume 30% production efficiency and tooling life gain by using high
pressure coolant system
(8.477*15*4.03) - (8.477*.70*15*4.03) = 153.73 ----------------------------- cost saving per piece
15,695 / 153.73 = 102.09------------------------------ pay back after 103 units
153.73*100 = 15,373------------------------------ machining labor saving per
100 units
Design Concept 4
Design
•
Design Alternatives
– Trigger button
– Trigger lift assembly
– Flush handle
– Housing (rivet inserts)
– Collar (rivet inserts)
Trigger
• Advantages
– 10 Fewer Parts
– Cost Reduction $43.80
– Weight Reduction
• Disadvantages
– Testing
– Modification
Link Assembly
Selection Matrix
Design Concepts 1 (Materials) 2 (Manufacturing) 3 (Machining)
4 (Design)
Specifications
Cost
2
2
1
1
Plating
1
1
1
1
Durability
2
1
1
1
Functionality
1
1
1
2
External Geometry
1
1
1
1
Weight
2
2
1
2
Thermal Performance
0
0
1
1
Total
9
8
7
9
Recommendation
•
•
•
•
Replace collar and housing material with PEEK, 30% carbon reinforced
Redesign consistent with the material change to reduce the overall cost
Use injection molding instead of casting & machining
Remove link assembly (130331-5)
–
Due to qualification by similarity to H3412-1 in which the link assembly is not included *
*Independent Testing Laboratories, Inc. Test Report No. TR9500
Timeline
7th week
8th week
9th week
10th week final week
Summary
•
•
•
•
•
•
•
Analyzed Cost Auditor Quote
Identified Four Most Expensive Parts
– Housing, Handle, Collar, and Actuator
– 55% of total manufacturing cost
Researched on:
–
Alternative Materials
• PEEK (Polyetheretherketone)
• PAEK (Polyaryletherketone)
• NORYL
• ULTEM
– Alternative Manufacturing Processes
• Injection molding
• Roll forming
• Compression molding
– Alternative machining processes
• Net-shape forming
• Outside processing (O/P)_
• Machine optimization: hardware and software
– Alternative designs
Down selection
Proposed design
– Replace Aluminum Alloy with Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced in housing and collar
– Injection molding of collar and housing instead of casting and machining
Wearability good for the proposed design
Cost saving: ( $1,302.46 v.s. $1,071.45)
– $231.01 decrease in total manufacturing cost