NEW FAST WIRE SCANNER 2013-2015
Manufacturing review
Emilien Rigutto - 19.06.15 1
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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
Emilien Rigutto - 19.06.15
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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
Emilien Rigutto - 19.06.15
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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 - 19.06.15
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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 - 19.06.15
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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 - 19.06.15
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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 - 19.06.15
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 - 19.06.15
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 - 19.06.15
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 - 19.06.15
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 - 19.06.15
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 - 19.06.15
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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1. J3010290 Drum and internal parts, proto 1, 2013-2014
SPSBWSRE0005 x1
Emilien Rigutto - 19.06.15
15
1. J3010290 Drum and internal parts, proto 1, 2013-2014
SPSBWSRE0005 x1
Emilien Rigutto - 19.06.15
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1. J3010290 Drum and internal parts, proto 1, 2013-2014
Emilien Rigutto - 19.06.15
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
Emilien Rigutto - 19.06.15
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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3. J3021655 Drum and internal parts, proto 2, 2014-2015
Emilien Rigutto - 19.06.15
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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3. J3021655 Drum and internal parts, proto 2, 2014-2015
Emilien Rigutto - 19.06.15
- 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
Emilien Rigutto - 19.06.15
- 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)