NEW FAST WIRE SCANNER Manufacturing review Emilien Rigutto
Summary Emilien Rigutto J Drum and internal parts prototype 1 2. J Vacuum tank 3. J Drum and internal parts prototype 2 4. Conclusion
1. J Drum and internal parts, proto 1, SPSBWSRE0011 x1 Subcontracting to POLMANS (BE), CA , 2721 CHF, report , no conformities detected. -SPSBWSRE0010 / 0008 x1+1 Raw material purchase INCONEL : 640 CHF. -SPSBWSRE0021 x1 Emilien Rigutto
1. J Drum and internal parts, proto 1, SPSBWSRE0011 x1 Subcontracting to POLMANS (BE), CA , 2721 CHF, report , no conformities detected. -SPSBWSRE0010 / 0008 x1+1 Raw material purchase INCONEL : 640 CHF. -SPSBWSRE0021 x1 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto
1. J Drum and internal parts, proto 1, 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 -EB welding POS 2 et 4 -Semi finishing POS 4 -Roughing POS 3 -EB welding POS 3 et 4 -Finishing with «cradles» -Welding of POS 1 / 5 / 6 Emilien Rigutto Manufacturing process proto 1 : 39 Steps (turning, milling, forming, heat treatment, EB welding, wire cutting, cleaning, control, leak test…) Metrological report (edms ) : - Default of coaxiality and 0.03 between Ø 32 and 47 H7 Difficulties : -Deformation POS 3 -Concentricity of Ø H7 -Final machining with «cradles»
1. J Drum and internal parts, proto 1, SPSBWSRE0005 x1 Emilien Rigutto
1. J Drum and internal parts, proto 1, SPSBWSRE0005 x1 Emilien Rigutto
1. J Drum and internal parts, proto 1, Emilien Rigutto Cost analysis: -Stainless steel 316LN 3D forged purchase for POS 2, EDH (with 2 spares) = CHF (2.980 CHF / drum) -Raw material purchase, EDH (with 4 spares for the flange DN400) = CHF (7.780 CHF / drum) -Subcontrating shaft SPSBWSRE0011, CA , CHF -Purchase Inconel, 640 CHF -Mechanical operations (including tooling) : CHF -Welding and forming operations : CHF -Metrology operations : CHF -EB welding operations : CHF -Heat treatment : CHF -Total Job: CHF (cleaning not including) -Total only drum: CHF
2. J Vacuum tank, 2014 Emilien Rigutto Manufacturing of 2 tanks SPSBWSRE0002 -Standard tolerances (be careful coaxiality Ø190H7 : 0.4mm) -Manufacturing process : 45 steps -Spinning POS 8, OLSEN, CA Metrological report edms , OK Cost analysis (pour 1 tank) : -Material purchase : CHF -Mechanical operations : CHF -Forming and welding operations : CHF -EB welding operations : 780 CHF -Subcontracting of spinning : CHF -TOTAL : CHF
3. J Drum and internal parts, proto 2, Emilien Rigutto Different approach for the drum: - subcontracting a maximum mechanical operations for a mass production of 20 to 25 drums -Creating intermediate drawings -Price inquiry -CA Rottger’s (DK) Metrological report edms : OK
3. J Drum and internal parts, proto 2, Emilien Rigutto New manufacturing process, shorter, 24 steps. Costs analysis for the drum PROTO 2: -Material purchase: CHF -Mechanical subcontracting : CHF -Forming and welding operations : CHF -Mechanical operations: CHF -EB welding operations : CHF -Heat treatment : CHF -TOTAL : CHF Costs analysis for the drum PROTO 1: -Material purchase: CHF -Mechanical subcontracting : NO -Forming and welding operations : CHF -Mechanical operations: CHF -EB welding operations : CHF -Heat treatment : CHF -TOTAL : CHF Why differences : -Existing tools -Experience of the prototype 1
4. Conclusion Emilien Rigutto 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)