NEW FAST WIRE SCANNER 2013-2015 Manufacturing review Emilien Rigutto - 19.06.15 1

NEW FAST WIRE SCANNER 2013-2015

Manufacturing review

Emilien Rigutto - 19.06.15 1

2

Summary

Emilien Rigutto - 19.06.15

1. J3010290 Drum and internal parts prototype 1

2. J3014388 Vacuum tank

3. J3021655 Drum and internal parts prototype 2

4. Conclusion

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1. J3010290 Drum and internal parts, proto 1, 2013-2014

- SPSBWSRE0011 x1

Subcontracting to POLMANS (BE), CA5311295, 2721 CHF, report 1297365, no conformities detected.

- SPSBWSRE0010 / 0008 x1+1

Raw material purchase INCONEL : 640 CHF.

- SPSBWSRE0021 x1


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- SPSBWSRE0011 x1

Subcontracting to POLMANS (BE), CA5311295, 2721 CHF, report 1297365, no conformities detected.

- SPSBWSRE0010 / 0008 x1+1

Raw material purchase INCONEL : 640 CHF.

- SPSBWSRE0021 x1


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SPSBWSRE0014 x2

- Roughing the 2 parts

- Relieving heat treatment

- Final machining, turning of thin paroies (0.3mm) with specific internal mandrel

(new request from Dmitry : 0.2mm)

- Etching

- Electron beam welding

- Leak test


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SPSBWSRE0005 x1- Roughing POS 2 / 3 / 6

- Rolling, welding, calibration POS 4

- Heat treatment POS 2 / 3 / 4 / 6

- Finishing POS 6, semi finishing POS 2

- EB welding POS 2 et 6

- Finishing POS 2

- Roughing POS 4


- Semi finishing POS 4

- Roughing POS 3


- Finishing with «cradles»

- Welding of POS 1 / 5 / 6


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- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





8







- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





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- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





10







- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





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- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





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- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





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- Finishing POS 2

- Roughing POS 4



- Roughing POS 3





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»

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SPSBWSRE0005 x1


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SPSBWSRE0005 x1


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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 CHF

- Welding 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 CHF

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2. J3014388 Vacuum tank, 2014


Manufacturing of 2 tanks SPSBWSRE0002

- Standard tolerances (be careful coaxiality Ø190H7 : 0.4mm)- Manufacturing process : 45 steps- Spinning POS 8, OLSEN, CA5490086- Metrological report edms 1381812, OK

Cost analysis (pour 1 tank) :

- Material purchase : 6.737 CHF- Mechanical operations : 9.750 CHF- Forming and welding operations : 5.525 CHF- EB welding operations : 780 CHF- Subcontracting of spinning : 1.930 CHF

- TOTAL : 24.722 CHF

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Different approach for the drum: - subcontracting a maximum mechanical operations for a mass production of 20 to 25 drums

- Creating intermediate drawings- Price inquiry- CA5847257 Rottger’s (DK)

Metrological report edms 1473488 : OK

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- New manufacturing process, shorter, 24 steps.

Costs analysis for the drum PROTO 2:

- Material purchase: 9.000 CHF- Mechanical subcontracting : 8.526 CHF- Forming and welding operations :

3.380 CHF- Mechanical 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 CHFWhy differences :- Existing tools- Experience of the

prototype 1

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4. Conclusion


- Internal parts : - Internal manufacturing : possible- Subcontracting : 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)

Documents

NEW FAST WIRE SCANNER 2013-2015 Manufacturing review Emilien Rigutto - 19.06.15 1