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

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Presentation on theme: "NEW FAST WIRE SCANNER 2013-2015 Manufacturing review Emilien Rigutto - 19.06.15 1."— Presentation transcript:

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

2 Summary Emilien Rigutto - 19.06.15 2 1. J3010290 Drum and internal parts prototype 1 2. J3014388 Vacuum tank 3. J3021655 Drum and internal parts prototype 2 4. Conclusion

3 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 Emilien Rigutto - 19.06.153

4 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 Emilien Rigutto - 19.06.154

5 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.155

6 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.156

7 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.157

8 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.158

9 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.159

10 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.1510

11 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.1511

12 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.1512

13 1. J3010290 Drum and internal parts, proto 1, 2013-2014 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 - 19.06.1513 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»

14 1. J3010290 Drum and internal parts, proto 1, 2013-2014 SPSBWSRE0005 x1 Emilien Rigutto - 19.06.1514

15 1. J3010290 Drum and internal parts, proto 1, 2013-2014 SPSBWSRE0005 x1 Emilien Rigutto - 19.06.1515

16 1. J3010290 Drum and internal parts, proto 1, 2013-2014 Emilien Rigutto - 19.06.1516 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

17 2. J3014388 Vacuum tank, 2014 Emilien Rigutto - 19.06.1517 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

18 3. J3021655 Drum and internal parts, proto 2, 2014-2015 Emilien Rigutto - 19.06.1518 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

19 3. J3021655 Drum and internal parts, proto 2, 2014-2015 Emilien Rigutto - 19.06.1519 -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 CHF Why differences : -Existing tools -Experience of the prototype 1

20 4. Conclusion Emilien Rigutto - 19.06.1520 -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)

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