design and manufacturing mman1130 final report · 4.1.10 conclusion ... the purpose of this report...

Design and Manufacturing MMAN1130

Final Report

GROUP THURSDAY-12-17-2

FIRST NAME

LAST NAME

ID

MARK

1 LIZA CHAO 3 4 6 3 3 1 9

2 JESSICA CHEN 3 4 6 1 9 5 8

3 GAVIN CHENG 3 4 6 3 2 2 8

4 ALVIN CHUNG 3 4 6 3 3 2 0

5 NADAV COHEN 3 4 6 0 6 9 6

Semester 1-2014

School of Mechanical and Manufacturing Engineering

The University of New South Wales

Table of contents

1.0 Executive summary…………………………………………………………………..………….3

1.1 List of Illustrations………………………………………………………….……………4

2.0 Introduction…………………………………………………………………………….…………4

2.1 Purpose……………………………………………………………………….………….4

2.2 Background…………………………………………………………………….………...4

2.3 Scope……...………………………………………………………………….…………..5

2.4 Procedure …………………………………………………………………….………….5

3.0 Materials Selection ………………………………………………………………….……..…....6

4.0 Individual Components………………………………………………………….………….……7 4.1 Base……………………………………………………..…….………….….…..7

4.1.1 Conceptualisation…...………………………………………………..………7

4.1.2 Initial design prototype…...……………………………………………..……8

4.1.3 Final design prototype…...…………………………………………...…….8

4.1.4 Prototype manufacture…...…………………………………………..….…9

4.1.5 Prototype testing and analysis ................................................................9

4.1.6 High volume design…...……………………………………………..........10

4.1.7 High volume manufacture…...……………………………………………10

4.1.8 Economic analysis…...………………………………………………........11

4.1.9 High volume analysis…...……………………………………………...…13

4.1.10 Conclusion…...…………………………………………………...............13

4.2 Piston…...……………………………………………………...………………………14

4.2.1 Initial design prototype…...……………………………………………....14

4.2.2 Final design prototype…...…………………………………………........14

4.2.3 Prototype manufacture…...………………………………………...…...14

4.2.4 Prototype testing and analysis…...……………………………………..15

4.2.5 High volume design…...…………………………………………………15

4.2.6 High volume manufacture…...……………………………………….…15

4.2.7 Economic analysis…...………………………………………….….…...16

4.2.8 High volume analysis…...……………………………………….…..….18

4.2.9 Conclusion…...………………………………………………….............18

4.3 Piston Housing…...………………………………………………………….………19

4.3.1 Initial design prototype…...………………………………………….…19

4.3.2 Final design prototype...………………………….…………................19

4.3.3 Prototype manufacture…...……………………………….……………20

4.3.4 Prototype testing and analysis…...…………………………..……….20

4.3.5 High volume design…...………………………………………...….….20

4.3.6 High volume manufacture…...……………………………..…………20

4.3.7 Economic analysis…...…………………………………………….......21

4.3.8 High volume analysis…...………………………………………..........22

4.3.9 Conclusion…...………………………………......................................23

4.4 Cover…...…………………………………………...…...………………….………23

4.4.1 Initial design prototype…...……..……………………………….…....23

4.4.2 Final design prototype…...………………………………………........23

4.4.3 Prototype manufacture…...……………………………......................24

4.4.4 Prototype testing and analysis..........................................................25

4.4.5 High volume design…...……………………….…………...................25

4.4.6 High volume manufacture…...……………...……………………..…26

4.4.7 Economic analysis…...…………………………….............................27

4.4.8 High volume analysis…...…………………………............................28

4.4.9 Conclusion…...……………………………….....................................28

4.5 Valves…...………………………………………….…...…………………………29

4.5.1 Initial design prototype…...………………………………………..….29

4.5.2 Final design prototype…...…………………….……..........................29

4.5.3 Prototype manufacture…...…………………………...……………...29

4.5.4 Prototype testing and analysis…...………………………………..…30

4.5.5 High volume design…...……………………………..........................30

4.5.6 High volume manufacture…...…………………………..………..…31

4.5.7 Economic analysis…...……………………………..…………..........32

4.5.8 High volume analysis…...……………………...................................32

4.5.9 Conclusion…...…………………………...........................................33

5.0 Conclusion…...……………………………......………………………………..…33

6.0 Reflection…...…………………………..………………………………………….34

7.0 References…...…………………..…………………………………………..……35

8.0 Contributions….…………..…………………………………………………….…37

9.0 Appendix…………………..…………………………………………………….…38

1.0 Executive summary

The purpose of this report is to detail the process and analysis of designing and

manufacturing a PP175 pneumatic vertical displacement pump prototype in accordance

to ‘Solo Pump Australia’s’ specifications. It also features the method of manufacture and

design for a high volume design concept of the pump based on the outcome of the

prototype when tested. Group members initially had individual concept sketches of the

pneumatic pump. The best design was chosen as the basis of the prototype design for

the entire group. The group strived to attain an easily manufactured, cost effective

design with maximum volume displacement within the specified range of 20-22.5cm3.

The dimensions of each individual component were based on the specifications given

by ‘Solo Pump Australia’. Each member was designated a component of the pump to

construct an engineering drawing, routing chart and routing sheet. Following this, each

member was then allocated another team members component to manufacture the part.

Upon completion of each individual component the pump was assembled and tested on

a jig at 250rpm. From the results during testing, these observations were taken into

consideration when developing a modified concept design for high volume

manufacturing. The observations made during testing were that the pump had

performed effectively only when air was prevented from entering the inlet valve due to

gravitational complications on the ball bearing. The pump managed to blow up the

balloon in a short period of time, thus proving its success. A new design for the valve

was then constructed and slight improvements were made on the other individual

components of the pump, increasing its lifespan and overall aesthetics. The choice to

die-cast the pump when manufacturing for high volume has allowed the production and

manufacturing of the pump to be of greater efficiency and cost effectiveness.

1.1 List of Illustrations

Table 1: Most important physical properties of aluminium and steel……………………..7

Table 2: Sand Casting compared to Die Casting (base)………………………………….11

Table 3: Cost Comparison between sand casting and die casting (base) ……………..12

Table 4: Cost comparison between sand Casting and die Casting (piston)…………....17

Table 5: Cost comparison between sand casting and die-casting (piston housing)…...22

Table 6: Cost comparison between sand casting and die-casting (cover)..........….…...27

Table 7: Sand casting compared to die casting (valves and cap)..................................32

2.0 Introduction

2.1Purpose

The purpose of this project is to design and develop a PP175 pneumatic vertical

displacement pump. Through the knowledge-based learning about specific

manufacturing documentation and high volume manufacturing processes students are

enabled to gain a basic introduction to manufacturing engineering and management.

2.2 Background

‘Solo Pump Australia’ requested that the product development team is to design and

manufacture a PP175 vertical displacement pump. The design must be of minimum

weight and maximum functionality given the design specifications.

2.3 Scope

The design specifications were:

● Pneumatic

● High Volume Market

● Long Life Components

● Five Components: Base, Piston Housing, Piston, Cover, Input/output

Valves

● Base: Maximum Dimension of 100mm x 70mm

● Vertical Piston Travel

● Piston Housing: Maximum Envelope Dimension of 50mm x 50mm

● Displacement Volume: 20 cm3 to 22.5cm3

● Piston: 10mm diameter shaft with 6mm hole (hole is 10mm below base at

top of stroke.)

● Base: 10mm hole has a +0.1mm tolerance.

● Material will be selected from the attached material list.

● Keep Maximum Functionality and Minimum Weight in mind.

● Prototype will be tested on a Jig.

● Base: Include two parallel slots; designed to suit M5 bolts.

● Pump will operate at 250 RPM.

● Pump will be connected to crankshaft through the 6mm hole.

2.4 Procedure

After developing individual concept sketches, group members collaborated and

discussed each other’s designs keeping in mind of the design specifications. It was

agreed that the design should be easily manufactured, cost effective and have the

maximum volume displacement within the given restrictions. From these features the

product development team was able to establish the dimensions of each component.

Each member was assigned a component to produce the engineering drawing, routing

chart and routing sheet in order to manufacture the prototype. Each member was then

assigned another team member’s component to manufacture the part. Once the

components were manufactured the pump was assembled and tested to determine its

functionality and efficiency. The results observed during the testing were analysed and

used to determine a final design for high volume manufacturing.

3.0 Material selection

The material used to make the pump will drastically determine the cost and efficiency of

the pump. The two main options were steel and aluminium. The low density of

aluminium in comparison to steel means a lighter material to work with, thus giving

aluminium a high strength to weight ratio. Aluminium is susceptible to vibrations, but

with the close-fitting design of the piston with the housing and the secure bolting to the

cover and base these vibrations would be minimised. The value of aluminium’s young’s

modulus from table 1 is a measure of elasticity. Young’s modulus for aluminium is less

than steel indicating its greater malleability and elasticity over steel. (Aluminium vs.

steel: general similarities) This property highlights that aluminium is more likely to

deform when a large load is placed on it. However since only air is being pumped the

effect of the pump is negligible.

Steel is a tough metal that is more susceptible to cracking during the spinning process

when being designed into intricate designs such as the individual components of the

pump. Aluminium is corrosion resistant without any further treatment and doesn’t rust

whereas steel needs to be painted or treated afterwards to protect it from rust and

corrosion. Aluminium is a lighter material and thus less work is needed to move the

piston up and down. Therefore aluminium is the chosen material for the pump, also it is

cheaper than steel. As all of the components of the pump are of the same material, they

would both all expand and contract equally in same ratio during thermal expansion. Due

to the equal thermal expansion rates this will not compromise the functioning of the

pump allowing all the components to work in unison independent of the thermal

expansion experienced.

Property Aluminium Steel

Density, ρ Kg m−3 2,700 7,800

Young modulus, E N mm−2 70,000 210,000

Shear modulus, G N mm−2 27,000 81,000

Poisson ratio, ν 0.33 0.3

Coefficient of linear thermal expansion, α K−1 23 × 10−6 12 × 10−6

Table 1: Most important physical properties of aluminium and steel (aluMATTER: Aluminium v. steel: general similarities)

4.0 Individual components

4.1. Base

4.1.1 Conceptualization

The first thing that was considered when designing the pump base was fitting the

criteria that ‘Solo Pump Australia Ltd’ specified. They required a ‘PP175 Vertical

Displacement Pump’ that must be of a pneumatic nature. In terms of the pump base,

the base must have dimensions of 100mm x 70mm and have a 10mm diameter hole for

the piston shaft to fit through. The tolerance allowed between the hole and the shaft is

+0.1mm due to the transformation of circular motion to linear motion. The prototype

base must also have two parallel slots that are designed to fit M5 bolts so that the base

can be fixed onto the jig.

This criteria created the bulk of the design concept for the base but what was missing

was how the base was to be attached to the piston housing. A few concepts were

considered such as making a round hole for the piston housing to be fixed on top and

using nuts and bolts to secure it. These concepts will be discussed further in the next

sections.

The last step was to consider the type of material that was to be used to create the

prototype in which the two choices were either: aluminium or mild steel. Though

aluminium was slightly more expensive than that of the steel, it provided a lightweight

base and had a very smooth surface finish adding to quality to the product. Aluminium

also has high malleability and excellent corrosion resistance as compared to mild steel.

This cost-benefit analysis will be examined in the economic analysis section.

4.1.2 Initial design prototype

According to the functional specifications, the base was to be a 100mm x 70mm

aluminium flat bar of 10mm thickness. There would be two parallel M5 slots of length

55mm that were 10mm away from the widths of the base. The 10mm diameter hole for

the piston shaft was to be at the centre of the base for aesthetic reasons and also to

evenly distribute the stress across the base. Our initial design prototype had a circular

groove on the base that was designed to have the piston housing sit within and this

groove also contained an O-ring to prevent any air leakages. M3 hexagonal socket

head screws were to be used to fix the base tightly with the piston housing. Therefore

there must be four M3 tapped counterbore holes, each 19mm up and 19mm across

from the centre hole.

4.1.3 Final design prototype

The final design prototype remained mostly the same but it was altered to minimise the

manufacturing time whilst maintaining the same high level of functionality. The circular

groove was dismissed because our analysis demonstrated that air leakages below the

piston did not affect the amount of air being displaced during the strokes. The holes for

screws remained in the same position but were changed to M5 bolts because of its

higher stock availability. These counterbore holes are also not tapped because the

analysis showed it was unnecessary, reduced the efficiency of assembly and increased

the risk of misfitting.

4.1.4 Prototype manufacture

To manufacture the base for the pump, a 100mm x 10mm bar stock of aluminium was

ordered of length 75mm. The dimensions of the base were inspected using Vernier

Callipers before being put into the milling machine where the carbide cutter reduced the

dimensions to 100 x 70 x 10 at speed 320 RPM and feed 50mm/min. All points of

interest such as holes and slots are marked out using Vernier callipers, centre punch,

set square and a metal scriber. The M5 parallel slots of length 55mm are then milled

using a slot drill where coolant is being used during the process before being inspected

again. The slot drill operates at speed 16m/min and at feed 50mm/min.

The drill press is then used to create the 10mm diameter hole at the centre of the base

plate using a 10mm drill bit at speed 32m/min. The counterbore holes are made in a

different manner where 5mm diameter holes are drilled straight through at the marked

positions at speed 16m/min. The holes are then drilled with a counterbore from the

bottom at depth 5mm to allow for the head of the screws to fit within the base. The

component then has its final inspection using the Vernier callipers and telescopic

gauges, and any sharp edges/burrs are to be removed using a ‘second cut’ file (see

Appendix A for base drawing).

4.1.5 Prototype testing and analysis

The testing demonstrated that the prototype was successful in completing its functions

of supporting the piston housing, fixing itself onto the jig firmly as well as allowing the

piston to move smoothly up and down the centre hole. However, care must be taken

when marking the position of the holes and drilling them correctly afterwards to ensure

the tolerances do not exceed the allowed amount of +0.5mm. This will increase the

efficiency of assembly of all the components to make the pump.

4.1.6 High volume design

The design for the high volume production of the pump base remains the same even

though the method of production has changed from machining to die casting. For high

volume, the product manufacturing process must be reliable, cost-effective, and create

accurate components that are consistent with each other.

4.1.7 High volume manufacture

The two alternative ways of producing the base in high volume are sand casting and die

casting. Sand casting involves pouring the molten aluminium into an empty cavity

shaped by a sand mould whilst die casting (cold chamber) involves injecting the molten

metal at high pressures into typically a hardened steel mould.

To create the base using the sand casting method, the startup time (including the

creation of the patterned sand moulds) requires a few days with low initial costs (West

Coast Castings Inc). Sand casting is cheaper when manufacturing in low volume due to

its low start-up costs but it is more expensive when run in high volume.

Cold chamber die casting can take up to several weeks to start-up and it is expensive to

set up but it has significant advantages over sand casting. Die casting uses a non-

expendable cast that does not need to be replaced and creates a smoother surface

finish, thus further machining the component within tolerance is not necessary. It is also

a faster process and therefore requires less labour (which minimises costs) as seen in

table 2. This is important for the manufacture of the base because the base must fit onto

the jig and its dimensions must be accurate to support the piston housing.

Sand Casting Die Casting

Startup

Time

A few days Several weeks

Initial

Expense

Inexpensive Expensive

Labor

Costs

Higher labor costs on

long runs

Lower labor costs on long runs

Finish Pebbly Smooth

Alloys High temperatures High fluidity materials; Better life with lower

temperatures (e.g., zinc)

Product

Size

Unlimited Casting weight must be between 30 grams (1

oz) and 10 kg (20 lb).

Casting must be smaller than 600 mm (24 in.).

Wall

Thickness

Thicker than die

casting

Thinner than sand casting

Table 2: Sand Casting compared to Die Casting (WCCI, 2014, Online)

4.1.8 Economic analysis

The values that are being used in this analysis were extracted from the company

‘Kinetic Die Casting’ in which the tooling costs for both sand and die casting are

compared. For the cost of material, UNSW School of Mechanical and Manufacturing

has provided the cost per metre of 100mm x 10mm bar (see Appendix C for material

costs). The estimated time taken to manufacture one component from sand casting was

15 minutes whilst the time taken by die casting was 12 minutes (see Appendix B for

base routing chart).

Cost of material per part: $56 x 0.07mm = $3.92

Cost of tooling for sand casting: $1,620/10,000 parts

Cost of tooling for die casting: $23,750

Cost of Labour: $25/ hour

Quantity Sand Casting Die Casting

1000 parts Tool Costs

Labour Costs

Totals Costs

$3920 $1620 $6250

$11,790

$3920 $23,750 $5000

$32,670

10,000 parts Tool Costs

Labour Costs

Totals Costs

$39,200 $3240

$62,500

$104,940

$39,200 $23,750 $50,000

$62,950


Labour Costs

Totals Costs

$196,000 $16,200 $312,500

$524,700

$196,000 $23,750 $250,000

$469,750


Labour Costs

Totals Costs

$392,000 $32,400 $625,000

$1,049,400

$392,000 $23,750 $500,000

$915,750

Table 3: Cost Comparison between sand casting and die casting

From Table 3, for the high volume production of 100,000 aluminium pump bases, the

estimate cost per part by sand casting is $10.49 whilst by die casting it is $9.15. For low

volume production, it is more feasible to use sand casting for its low start up cost but it

less viable in the long run due to the large labour costs and tool costs.

4.1.9 High volume analysis

Die casting is demonstrated to be the most efficient and cost-effective way of producing

the pump bases in high volumes. This is because the die/cast is reusable and has a

very smooth surface finish eliminating unnecessary further machining. Aluminium is also

the most viable material to be used in this process because of its corrosion resistance,

thermal conductivity, low density and strength under high temperatures (SAPA, 2014,

Online).

4.1.10 Conclusion

The design of the base was created to maximise efficiency and functionality under the

set criteria by Solo Pump Australia Ltd whilst minimising costs. The prototype’s design

was finalised after feedback from the testing of the pump and this design remained the

same for the high volume production of the component. The pump base would be

created from aluminium due to its superior qualities such as low density and smooth

surface finish (i.e. high malleability). Die casting was determined to be the most feasible

method of manufacturing high quantities of the base as stated in the high volume

analysis.

Alvin Chung (z3463320)

4.2 Piston


Before the initial design of the prototype for the piston, the functional specifications for

the whole pump had to be established. These included the type of pump (vertical

displacement pneumatic pump); the displacement volume (range of 20-22.5cm3) and

the piston having a 10mm diameter shaft (see Appendix C for design specifications).

After the considerations listed, calculations were made in order to maximise the

displacement volume with the given design restrictions. Thus, the dimensions for the

piston were established (see Appendix A for piston drawing ) with a stroke length of

30mm. The whole initial design process for the entire pump was done in collaboration.


The final design of the piston prototype remained unchanged except for the O-ring

groove. After collaboration and consideration of the dimension of the piston head, it was

finalized that the Ludowici O-ring C.S. 1.5 is most suitable. Thus the dimensions of the

groove for the O-ring is established and adjusted on the final prototype engineering

drawing (see Appendix A for piston drawing).

The type of material for piston to be aluminium was also determined during

collaboration after consideration between the stocked material; steel and aluminium.

Aluminium was chosen due to its low density, higher malleability and its resistance to

corrosion compared to steel, which is favourable for a dynamic parts such as the piston.


In order to manufacture piston for the prototype, a piece of aluminium stock sized at a

39mm diameter and 65mm depth is cut. The raw material is inspected; ends are faced

and cut to a 64mm height using the lathing machine. The O-ring groove is first

manufactured with a specific tolerance as specified, and then the shaft diameter is

lathed until it is 10mm (see Appendix A for routing sheet). The speed at which the piston

is lathed during this process is slow to ensure a smooth machine surface finish,

reducing friction between the piston and the rest of the components.


After the prototype was assembled, it was tested using a jig at 250 RPM as specified in

the design specifications. The testing was successful which demonstrated that the

pump is fully functional. On the other hand, due to the designed length of the piston and

precision of the manufactured length of the shaft, it was miscalculated that the stroke

length is 25mm instead of 35mm. However, this did not drastically affect the

functionality of the pump as a whole since the displacement volume remained constant

as well as reduced the likelihood of knocking.


For manufacturing in high volume it is recommended that the piston part to be casted.

This however will affect the properties of the material as the piston is manufactured.

Therefore, some changes are made to the design. Every right angle of the piston except

for the O-ring groove is filleted. This is because right angles are structurally weaker

when casted and the stress concentration between the piston head and shaft is

reduced. The O-ring groove however remains the same as the specific dimensions are

given by the manufacturer of the O-ring.


One method of manufacturing the piston in high volume is by cold-chamber die casting.

Cold-chamber die casting requires the aluminium to be in molten form. After the molten

aluminium fills the cavity when the die is closed, a plunger pushes the metal in

pressures over 70,000 kPa until the aluminium solidifies. The die is then opened, the

ejector pins push out the casting and the whole process repeats (Dynacast, “Cold-

Chamber Conventional). The advantage of die casting the piston is that it is time

efficient, low physical labour cost, highly accurate and consistent and high quality parts

are produced. Disadvantages however include the high cost of the machine, and also

as mentioned in the previous section, right angles are structurally weaker which this

affects the manufacturing of the O-ring groove. Therefore after die casting the piston,

the groove must be turned using a lathing machine.

Another method of manufacturing the piston is by sand casting. Sand casting involves

placing half of the pattern in a box where “green sand” (which consists of sand with 2-

3% clay and water) is compressed on top of it. The process repeats for the other side of

the pattern after flipping over the first mould, placing talcum powder on the surface,

marking the pouring basin and placing another box on top of it. The pouring basin is cut

out and the pattern is then carefully pulled out. Molten aluminium is poured into the

cavity, thus producing the shape. Advantages of this method of manufacturing the

piston are that it is initially lower in cost to manufacture parts from and the sand mould

is recyclable making it “essentially pollution free” (Classroom Video, “Metal Casting:

Sand Moulds”). Disadvantages of this method include that it is more time costly, labour

intensive, and more likely to have defects due to gas holes and shrinkage porosity

compared to die casting (Enginsoft, “Aluminium Sand Casting”).


Based on the company “Kinetic Die Casting”, given cost comparisons between die

casting tooling and sand casting tooling (Kinetic Die Casting, “Sand Casting Tooling

Cost VS Kinetic Die Casting Tooling Cost”), and the provided cost per metre of material

from the UNSW School of Mechanical and Manufacturing Engineering (see Appendix C

for material costs), a rough estimation of the cost per part can be calculated. All costs

are converted to AUD.

Cost of material per part: $105.33 x 0.065mm = $6.85

Cost of tooling for sand casting: $1,620

Cost of tooling for die casting: $23,750

Cost of tooling for lathe turning machine: $6,000

Cost of labour: $25/hr

Quantity Sand Casting Die Casting

1,000 parts Tool Cost

Labour Cost

Total Cost

$6,850 $7,620 $8,333

$22,803

$6,850 $29,750 $5,417

$42,016


Labour Cost

Total Cost

$68,500 $7,620

$83,333

$159,453

$68,500 $29,750 $54,167

$152,417


Labour Cost

Total Cost

$342,500 $9,240

$416,667

$768,407

$342,500 $29,750 $270,833

$643,083


Labour Cost

Total Cost

$685,000 $12,480 $833,333

$1,530,813

$685,000 $29750

$541,667

$1,256,417

Table 4: Cost comparison between Sand Casting and Die Casting

From the cost calculations in Table 4, it is clear that in quantities below approximately

7,500 that sand casting is the preferred choice of manufacturing due to its lower cost.

However, in higher volume manufacturing die casting is the most cost effective way of

producing the piston, since a sand casted aluminium piston would cost approximately

$15.30 per part to manufacture, compared to a die casted aluminium piston costing

approximately $12.56 per part.


Based on the comparisons made between sand casting and die casting, it is concluded

that the most effective way to manufacture the piston part in high volume is by die

casting. This is because it is the most cost effective, time efficient, accurate and

consistent, and produces a higher quality finish.

4.2.9 Conclusion

Overall, the design for the aluminium piston is unchanged apart from filleting right

angled edges due to adapting to the die casting process in high volume manufacturing.

However, the manufacturing of the O-ring groove remains the same for both prototype

and high volume processes due to specific dimensions specified by the manufacturer of

the O-ring C.S. 1.5. In high volume, it is concluded overall that the most practical way to

manufacture the piston is by die casting due to the reasons as stated in the high volume

analysis.

Jessica Avedawn Chen (z3461958)

4.3 Piston Housing


The dimensions of the piston housing were determined by the requirements according

to ‘Solo Pump Australia’s’ requests. The company required a pneumatic vertical

displacement pump with a displacement volume of 20-22.5cm3. The stock sizes given

along with the requirements by Solo Pump Australia limited our sizing of the piston

housing. The dimensions of each individual pump were discussed as a group based on

everyone’s initial design concept drawings. The best design was chosen and the

individual components of this design were looked into further detail. The piston housing

size was then determined to be a 50mm diameter cylindrical tube of height 52mm in

height with a hole in the centre with same diameter of the piston. A small 3mm in

diameter inlet hole on one side of the housing was designed to allow air to collect in the

housing. Eight tapped holes on the top and bottom were added be used to screw the

cover and base to.


After careful consideration, the initial design was changed. The piston housing was no

longer a cylindrical shape, but instead we chose to use a 50mmx50mm square block of

aluminium. This allowed us to use larger bolts to screw the cover and base together for

more stability (change from M3 to M5 bolts). The inlet hole on the side was removed

and an extra valve was added instead. This reduced the height of the housing to 49mm.

An O-ring groove was also added to ensure air did not escape from the joining of the

cover and piston housing with an outer diameter of 47mm and an inner diameter of

43mm. This was also to ensure a secure fit between the two components.


Manufacturing a prototype of the piston housing saw ordering a stock size of

50mmx50mmx50mm block of aluminium. The top and bottom surfaces were faced off

and used as datum edges. The 39mm diameter centre hole was drilled along with an

addition 8 holes were drilled on top and bottom of the piston housing for the bolts to go

through. The O-ring groove was lathed and threads were added to the eight holes on

the housing (see Appendix A for routing chart).


The testing of the piston housing along with other components once the pump was

assembled proved to be a success as the pump worked efficiently. However the inlet

valve did not work as assumed. Once the inlet valve was blocked however the pump

blew up the balloon in a matter of seconds.


The high volume design for the piston housing was changed to decrease stress

concentrations. The overall dimensions have been kept the same, however the vertical

straight edges of the housing have been filleted to a 2 mm radius (see Appendix B for

housing drawing). The continuity of the sides of the piston housing will distribute stress

more evenly to its neighbouring areas as the straight edges act as stress raisers.

(Lesson 2: stress concentration).


There are two main methods to manufacture a high volume of piston housings, that

being sand casting and die-casting.

The sand casting process involves creating a mould out of sand for the prototype, and

molten metal is poured into this mould. Cold chamber die-casting is when the molten

metal is poured into the injection cylinder and then quickly injected into the die under

pressure (Die casting methods). Metal is melted, poured into the holes to fill the mold,

and left to cool. When the cast part has cooled, the box is opened and the part is

removed. Sand casting will be cheaper initially as the sand used for the mold is

reusable and cheap. Sand casting also has a quick set-up time of a few days in

comparison to die casting, which may take up to several weeks. Die casting is initially

expensive as the mould is made of a hardened tool steel to withstand high pressure and

temperature, however it will take a shorter time to break even and will be cheaper in the

long run. (Sand casting compared to die-casting).

Die casting also has a smoother finish than sand casting and is better suited to pieces

with smaller wall thicknesses in comparison to sand casting. Since the casting weight is

above 30g die casting may be used. Costs for sand casting is high due to the sand

being disturbed when the part is removed, thus the set up operation must be repeated

for each part. Sand castings tend to have a grainy surface with poor dimensional

control. Most often castings are machined in post processing operations for smoothness

and dimensional integrity. Therefore die-casting is a more suitable process for making

the piston housing in high volume. Having the piston housing die-casted will reduce the

process of manufacturing to casting the mould and tapping M5 holes into the top and

bottom holes of the housing.


The sand casting tools for aluminium range from $500 to $7,500 depending on the part

being made. Each casting part for the sand casting tool has a life of 5000 parts. While

the die casting tools for aluminium range from $5000 to $75,000 depending on the part

being made, this is ten times the price of sand casting. However the life of die-casting is

range from 100,000 to 1,000,000 parts, which is an increase of 20 to 200 times the life

of sand casting (Sand Casting Tooling Cost VS Kinetic Die Casting Tooling Cost). Table

5 shows that die-casting is more economically efficient than die-casting.

Number

of parts

Sand casting Die casting

10,000 Material: $8,800 ($0.880 per part)

Production: $17,372 ($1.737 per part)

Tooling: $2,424 ($0.242 per part)

Total: $28,595 ($2.860 per part)

Material: $8,860 ($0.886 per part)



Total: $33,742 ($3.374 per part)




Total: $71,966 ($2.879 per part)




Total: $56,461 ($2.258 per part)



Tooling: $8,731 ($0.175 per part) Total:

$139,566 ($2.791 per part)




Total: $88,180 ($1.764 per part)




Total: $270,401 ($2.704 per part)




Total: $150,315 ($1.503 per part)

Table 5: cost comparison between sand casting and die-casting (Custom Part Cost Estimator)


From the prices seen in the table 5 above, it can be seen that die-casting is preferred

over sand casting economically. Also the requirements for the piston housing is more

suited to die-casting methods as it requires a smooth finish, and has thin walls in which

the sand casting is unable to produce. The smooth finish will allow the piston housing to

have a longer lifespan as it the moving parts of the piston against it will move smoothly.

4.3.9 Conclusion

The changes that the piston housing has seen has made the piston housing more

stronger and stable when assembled with the other components. Die-casting has been

chosen for production in high volume as it is more cost effective and is more suited to

the piston housing design requirements.

Liza Chao (z3463319)

4.4 Cover


Based on the functional requirements and constraints given by Solo Pump Australia,

each member of the group was tasked with creating one concept sketch each so that a

large variety of different solutions to the design problem could be obtained. These

concepts were gathered and notable features of a design were selected or combined to

make up the first design. The dimensions of the pump cover was determined using the

stock size in the materials sheet given by TAFE. A 50x50mm square block of aluminium

with a height of 10mm was selected for the prototype cover. Four threaded M3 and

counterbored holes with were made perpendicular to the top surface to allow bolts to

attach the cover to the housing. Similarly, a single M12 threaded hole was made in the

centre of the cover for an outlet valve to attach.


After a series of iterations to the initial design, in which the manufacture process was

considered, a final design prototype was created. The envelope dimensions of the part

remain unchanged, but the screw holes were enlarged to 5mm diameter (for an M5

bolt), threads and counterbore were removed (for a simpler design) and spaced closer

to the corners. This was because the housing was changed from a cylinder to a

50x50mm square (matching the cover), allowing for more free space on the cover

surface to put an enlarged bolt. The larger bolts allow for better attachment between the

two surfaces and hence better sealant. The inlet hole on the side of the housing was

changed to a inlet valve that was placed adjacent to the outlet valve at the top of the

cover. Some features originally designed for the valves were instead placed on the

cover to simplify the manufacturing process for the inlet valve. These included two small

holes drilled into the inlet hole to allow air to flow.


An aluminium block of 50mmx50mmx12mm was cut from the flat bar stock as ordered.

The height was ordered larger than necessary so that the top and bottom surfaces

could be faced and squared on a milling machine to the required dimensions as

necessary. The bottom surface should ideally fit level with the top of the housing to

create the a leak-proof seal between the top components while in operation. The four

5mm holes were drilled using the drill press. For the outlet valve hole , a 10mm hole

was drilled and tapped with an M12 bit through the entire component. For the inlet valve

hole, a 10mm hole was drilled with a flat drill bit and tapped with an M12 tapping bit until

3mm from the bottom. 2 holes of 1.5mm diameter were then drilled into the remaining

material in the outlet hole, allowing air to pass while stopping the ball. These holes were

made off-centre to eliminate the risk of the ball blocking them and thus blocking airflow.

No special surface finish is required, as there are no moving parts causing friction (such

as the piston moving against the housing). Hence a fast speed/feed rate is utilised in

order to minimise the time needed to manufacture the part.


Once the components were manufactured and assembled, the complete pump was

tested at 250 RPM as specified in the functional specifications. The pump was proven to

be fully functional in that it fulfilled its objective (popping the balloon). The cover itself

was securely attached to the housing and valves and the o-ring seal prevented leakage

of air as intended.

Although the prototype design of the cover was very successful, possible improvements

could be made including:

- Placing the inlet valve further away from the outlet valve. As the balloon

(attached to the outlet valve) expands, the sides of the balloon tend to partially

cover the inlet valve. This obstruction reduces the airflow into the pump chamber

and hence the rate at which the balloon is pumped.

- Combining the cover and housing into one component. The gap between the

attaching surfaces of either component allows air to escape while the pump is in

operation. To prevent this, an o-ring seal is created in the housing so that no air

will leak. This involves increased machining operations and an additional shelf

component. This could be avoided if the two components were combined,

reducing manufacturing time and simplifying the design greatly. However, as

stated in the functional requirements, there MUST be five components, so this

improvement should only be a consideration instead of a design.


The design for high volume was essentially the same for the prototype. The envelope

dimensions, manufacture material, size of holes, threads and the surface finish were

kept the same. However, as cold chamber die casting was the chosen manufacturing

process for high volume production, sharp corners and angles must be avoided (as they

act as stress raisers and cause cracking of the metal during solidification). As a result,

fillets of 2 mm radius have been used for the straight edges on the sides (continued to

the housing) and the top surface to reduce this stress concentration. This also makes

the cover slightly lighter.


There were two main manufacturing processes that were considered for the high

volume production: sand casting and die casting. A comparison of the two

manufacturing methods is given below in table 6.


Startup

Time

A few days Several weeks

Initial

Expense

Inexpensive Expensive

Labor

Costs

Higher labor costs on

long runs

Lower labor costs on long runs

Finish Pebbly Smooth

Alloys High temperatures High fluidity materials; Better life with lower

temperatures (e.g., zinc)

Product

Size

Unlimited Casting weight must be between 30 grams (1 oz)

and 10 kg (20 lb).

Casting must be smaller than 600 mm (24 in.).

Wall

Thickness

Thicker than die casting Thinner than sand casting

Sand Casting compared to Die Casting (WCCI, 2014, Online)



Quantity Required 100,000 100,000

Special Tooling Sand mould (negligible) Die Cost = $32,000

Fixturing N/A N/A

Process Equipment Machine cost = $120,000 Machine cost = $300,000

Direct Labour 2 workers ($30 / hour /

person)

1 worker ($30 / hour /

person)

Direct Material $1.40 / unit $1.40 / unit

Overhead Cost N/A N/A

Production Capacity <20 / hour / shift <200 / hour / shift

Production Cost $560,000 $487,000

Production Cost/unit $5.60 / unit $4.87 / unit

Table 6: comparison between sand casting and die-casting

It is evident that sand casting is more cost-efficient in low quantities, but as quantity

increases, die casting becomes more economical. For a production quantity of 100,000,

there is a total saving of $73,000 over sand casting if die casting is used. The sand

used for the mould is cheap and reusable whereas the dies/mould used for die casting

made of high-grade steel in order to withstand the high temperature and pressure, and

hence more expensive. The initial cost involved with die casting (purchasing of

equipment, tooling, set-up) is very expensive. However, in a high volume production,

the advantages offered by die casting (the speed at which the cast is made, significantly

less labour cost and quality of the cast) significantly outweighs the initial cost for the

setup. Die casting involves minimum labour as the process comprises of injection of

molten metal under high pressure into a cavity under gravity, which is performed

automatically by the process equipment. As a result, only one worker is required to

operate and manage the machinery. For sand casting, more manual labour is required

to break and remake a sand mould during each cast and two workers are required.

Manual machining is also required to achieve dimensional accuracy, leading to an

increase in labour cost.


Die casting is the fastest and most cost-effective way of producing components in high

volumes of 100,000 units. The casts have very good dimensional accuracy and very

smooth surface finish, so machining after casting is not required. Although they are

costly to produce, the dies are re-useable, and in a production size this large, time is

greatly reduced, making it more applicable for mass production than sand casting.

4.4.9 Conclusion

It can be seen from the iterations made to the design and manufacturing of the cover

over time, the design has greatly improved to be more functional and applicable to the

design and functional constraints. Aluminium as the material and die casting as the

manufacturing process are both ideal choices for high volume as they are cost and time

efficient and satisfy the functional requirements stated by the client company.

Gavin Cheng (z3463228)

4.5 Valves


Using the stock sizes of materials as a basis an initial design for the valve was

conceived. This design included a flap valve as an outlet with an outside diameter of

12mm and a small 3mm inlet hole placed in the piston housing to allow air into the

chamber when the piston is at the lowest point of its cycle. The valve was threaded to

provide a means of an airtight attachment to the cover. This design required a motor

strong enough to pull the piston while creating a low pressure chamber in the housing.


After some deliberation within the group the initial design was changed. The assumption

that the motor was strong enough to handle the low pressure created was dismissed

and thus an inlet valve was added to the top of the pump. These valves were also

changed from a flap valve to ball valves. The design for the ball valve included a

recessed groove to hold the o-ring but was then removed as it was too difficult to

manufacture. To allow for ease of manufacture the length of the valve was increased

from 30mm to 60mm. A solution had to be devised to allow air to pass through the

valves but stop the ball from escaping. This prompted a change in design of the cover

for the inlet valve and a dome nut, modified to allow air through the top, was added to

the outlet.


Manufacturing a prototype of the valve ordering a bar stock sized at 12mm diameter x

140mm cut of aluminium, an M12 Dome nut and two 7mm steel ball bearings. The bar

stock was cut in half to produce the basis for the two valves. A 6mm hole was bored

through the middle and a 7mm hole bored to a depth of 10mm. Finally an M12 thread

was tapped in the appropriate places on the valve.


The testing of the pump and specifically the valves proved to be partially successful. All

parts of the pump worked as expected with the exception of the inlet valve. This is due

to assumption made during the design of the pump that the force produced by the

piston will be enough to overcome the gravitational acceleration on the ball bearing in

the inlet valve. When the inlet valve was blocked the pump worked as expected.


Three designs for the production of the valves at high volume were considered. The first

reverts to the original idea of an inlet hole at the lowest point of the piston cycle as it

was proven in the prototype testing that the motor was powerful enough to overcome

the low pressure created when there is no intake of air at the pistons down stroke.

However as the power of the motor was never specified it was decided that the pump

must be compatible with motors of lower power and thus this design was discarded. The

other two designs for the valve were considered based on the different methods of

manufacturing, sand casting and die casting. However it was decided that sand casting

did not produce the surface finish required to create a proper seal. Thus die casting was

selected to as the preferred method of manufacture. The features of this valve are:

- The inlet and outlet valve were shortened and made identical to reduce the cost

of producing different parts. Although this creates a redundant thread on the inlet

valve reducing its aesthetics, the cost of production is greatly reduced and is thus

a necessary compromise. This thread could be used as an attachment point for a

hose if a gas other than air is used as an alternative. However this is not

recommended and would have to be further researched for the pumps

compatibility with these gases.

- A tapered ball chamber to eliminate the need for an o-ring thus reducing the

cost of the o-ring and assemblage of the pump.

- A die cast, hex head cap with the correct thread needed to screw onto the

valve. This is required due to the limitations of die casting in that the mould would

not be removable if the ball chamber was completely sealed. The hexagonal

shape of the cap allows for ease of assembly. Additionally the cap lowers the

cost of outsourcing and modifying a dome nut as a cap.

- Springs in both inlet and outlet valves. This eliminated the reliance on the motor

to produce enough force to overcome the effects of gravity on the ball. It also

allows the pump to be used in any orientation.


There are two main methods to manufacture a high volume of valves, machining and

die-casting.

Machining would use CNC lathes and mills to produce a high quality product. However

CNC machining is time consuming and wasteful of material (even if excess is recycled)

and thus is an expensive option when a high volume of valves is needed. Cold chamber

die-casting is when the molten metal is poured into the injection cylinder and then

quickly injected into the die under pressure (Die casting methods). Metal is melted,

poured into the holes to fill the mould, and it is left to cool. When the cast part has

cooled, the box is opened and the part is removed. Die casting is initially expensive as

the mould is made of a hardened tool steel to withstand high pressure and temperature,

however it will take a shorter time to break even with the machining option and will be

cheaper in the long run. While die casting produces a product with lower quality than

machining the process is sufficiently accurate for the purposes of this pump and the

compromise is necessary to reduce cost of production.

4.5.7 Economic Analysis

Machining Die Casting

Quantity Required 100 000 100 000

Special Tooling Tool Costs = $1000 Die Cost = $40 000

Process Machine cost = $150,000 Machine cost = $300,000

Equipment

Direct Labour 1 workers ($30 / hour / person)

1 worker ($30 / hour / person)

Direct Material $0.50 / unit $0.50 / unit

Overhead Cost N/A N/A

Production Capacity

<10 / hour / shift <400 / hour / shift

Production Cost $501 000 $397 500

Production Cost/unit

$5.01 / unit $3.98 / unit

Table 7: Cost comparison between machining and die casting


From the prices seen in the table 3 above, it can be seen that die-casting is preferred

over machining economically. This is due to the greatly decreased cost of production in

die casting in comparison to machining even when taking into account the higher quality

of machining with CNC.

4.5.9 Conclusion

The changes that the valves have seen have made them more efficient and cost

effective. Aluminium die-casting has been chosen for production in high volume as it is

more cost effective and is more suited to the valve design requirements.

Nadav Cohen (z3460696)

5.0 Conclusion

A prototype of the vertical displacement pump was designed, manufactured and tested.

The pump prototype had performed its purpose successfully and thus few changes

were made to the design for high volume manufacturing.

The results from the testing were used to alter the designs of each individual

component. The valve design for high volume has been altered to be able to adapt to

different orientations, thus overcoming the gravitational issue emphasised during

testing. All other variables of the components designs were maintained with extra fillets

added to reduce stress concentrations. The method of production was changed to die-

casting to increase accuracy, efficiency and cost effectiveness in comparison to the

previous method. The product development team has designed and manufacturing a

fully functioning PP175 vertical displacement pump prototype and analysed high volume

manufacturing methods. This process has enabled the product development team to

learn about specific manufacturing documentation and high volume manufacturing while

gaining a basic introduction to manufacturing engineering and management.

6.0 Reflection

CAD tutorial

All team members received the Solidworks tutorials equally in that they found them

useful and easy to understand. The tutors from were helpful and explained things

thoroughly with simple straightforward directions as opposed to the handbook given

which were slightly less helpful.

TAFE

All members favoured the Tafe sessions as it was engaging and interesting and

preferred this physical style of learning to the written method. The experiences gained

cannot be taught and thus were considered invaluable. The instructors at Tafe were

extremely helpful with all problems, they would check up on our job and our progress

frequently to ensure we understood everything. The instructors were patient and

genuinely concerned with our understanding and knowledge of the job at hand.

Lectures

All team members found the lecturer engaging and helpful but the content itself was at

times quite ‘dry’. A way to improve this is to maybe have interactive elements within

class and also set stronger expectations of what is to be learnt in the course. It is not

necessary to have a two hour lecture to cover the content but if it is to be two hours, a

break after every hour would be preferred. A strong learning point from the lectures is

when the content has a direct correlation with real world applications that we are aware

of. This was highlighted in the last lecture during the discussion of waste and the

afterlife of certain products.

7.0 References

Dynacast. (2014). COLD-CHAMBER CONVENTIONAL. Available:

http://www.dynacast.com/die-casting/die-casting-processes/cold-chamber. Last

accessed 2nd Jun 2014.

Enginsoft. (2010). ALUMINUM SAND CASTING. Available:

http://www.enginsoft.com/technologies/metal-process-simulation/aluminum-sand-

casting/. Last accessed 2nd Jun 2014.

Difference Between Sand Casting and Die Casting . 2014. Difference Between Sand

Casting and Die Casting . [ONLINE] Available at: http://info.cpm-

industries.com/blog/bid/328544/Difference-Between-Sand-Casting-and-Die-Casting.

[Accessed 04 June 2014].

Aluminum Casting Methods - Sand Casting and Die Casting Comparison. 2014.

Aluminum Casting Methods - Sand Casting and Die Casting Comparison. [ONLINE]

Available at: http://www.westcoastcastings.com/die-casting.html. [Accessed 04 June

2014].

Sand Casting Aluminum Parts compared to Aluminum Die Castings. 2014. Sand

Casting Aluminum Parts compared to Aluminum Die Castings. [ONLINE] Available at:

http://www.kineticdiecasting.com/sandcasting.html. [Accessed 04 June 2014].

Die Casting Process, Defects, Design. 2014. Die Casting Process, Defects, Design.

[ONLINE] Available at: http://www.custompartnet.com/wu/die-casting. [Accessed 04

June 2014].

Sand Casting Cost Estimator. 2014. Sand Casting Cost Estimator. [ONLINE] Available

at: http://www.custompartnet.com/estimate/sand-casting/. [Accessed 04 June 2014].

The benefits of Aluminium . 2014. The benefits of Aluminium . [ONLINE] Available at:

http://www.sapagroup.com/en/sapa-pole-products/aluminium/. [Accessed 04 June

2014].

Australia die casting association, Die casting methods, accessed: 2nd june 2014,

http://www.diecasting.asn.au/Services/ViewServices.asp?Ref=5535

Product Costing Guidelines, Integrated Product Development (IPD), by William Lovejoy,

Sebastian Fixson and Shaun Jackson, October 2005, Revised November 2008,

November 2010, Accessed: 1st june 2014

aluMATTER, Aluminium v. steel: general similarities, accessed: 1st june 2014

http://aluminium.matter.org.uk/content/html/eng/default.asp?catid=217&pageid=214441

7130

Wenzel Metal Spinning, Steel versus Aluminum - Weight, Strength, Cost, Malleability

Comparison, by Adam Hornbacher, accessed 3rd june 2014

http://www.wenzelmetalspinning.com/steel-vs-aluminum.html

Module 3: design for strength, Lesson 2: stress concentrations, Version 2 ME, IIT

Kharagpur, accessed 2nd june 2014

8.0 Contributions

Appendix A

Prototype

5

50

10

100

70

19

19

10

TOP VIEW

10

9

5

5.50

FRONT VIEW

ISOMETRIC VIEW

AS1100

TITLE

TOLERANCE UNLESS NOTED OTHERWISE

APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.5mm ALUMINIUM

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSWDRAWN BY PUMP BASE

1QTY

J.A. CHEN (Z3461958)FIRST RELEASE DATE

1.6

1/6/143

DIMENSION IN MILLIMETRES DRAWING NUMBER

A. CHUNG (Z3463320)

2/4/14J.A. CHEN (Z3461958)

SURFACE FINISH UNLESS NOTED OTHERWISE

1

SCALEMATL1:1

SolidWorks Student Edition. For Academic Use Only.

15

49

6 THRU

A

39

10

TOP VIEW

ISOMETRIC VIEW

1.9

5 0 0

1.35 -00.05

DETAIL A SCALE 2 : 1

AS1100

FRONT VIEWTITLE


APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.3mm ALUMINIUM

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSWDRAWN BY PISTON

1QTY

G. CHENG (Z3463228)FIRST RELEASE DATE

1.6

04/06/20143


J. A. CHEN (Z3461958)

06/06/2014G. CHENG (Z3463228)


2

SCALEMATL1:1


49

47

6

A

50 5

0

8 X M5 10 EQUALLY SPACED

6

47

43

39

1.2

0


TOP VIEWISOMETRIC VIEW

FRONT VIEW

AS1100

TITLE


APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.5mm ALUMINIUM

DRAWN BYHOUSING

1QTY

ALVIN CHUNG (Z3463320)FIRST RELEASE DATE

1.6

03/06/143


LIZA CHAO (Z3463319)

01/04/14ALVIN CHUNG (Z3463320)


3

SCALEMATL1:1

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSW


ISOMETRIC VIEW

FRONT VIEW

TOP VIEW

AS1100

A

5 HOLES EQUALLY SPACED

50

50

15

M12 M12 7 MIN LG

4x

R26.87

10

REV

TITLE

1:1

NOTED OTHERWISE

APPROVED BY

CHECKED BY

DATE

DO NOT SCALE

TOLERANCE UNLESS

A40.5mm ALUMINIUM

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSWDRAWN BY

PUMP COVER

1

QTY

NADAV COHEN (Z3460696)FIRST RELEASE DATE

MATL SCALE

1.6

02/06/2014

MILLIMETRESDRAWING NUMBER

GAVIN CHENG (Z3463228)

04/04/2014ALVIN CHUNG (Z3463320)

DIMENSION IN NOTED OTHERWISE

4

SURFACE FINISH UNLESS

3


1.5 2x

4

SolidWorks Student License Academic Use Only

Assembled Pump

Base

Base Plate 4x M3 Screws

Piston Housing

Housing Block

1x O-ring

Piston

Piston shaft/head

1x 0-ring

Cover

Cover Plate 4x M3 Screws

Valves

Dome Nut Inlet Tube Outlet Tube 2x Balls

800

Put 4xM3 hexagon socket head cap screw through base

801

Put O-ring on groove of piston head

Put piston shaft through base

802

803

Attach piston housing to base

Place O-ring on groove of piston housing

Attach pump cover with 4xM3 hexagon socket head cap screw

Place O-ring and ball in inlet valve

Place O-ring and ball in outlet valve

Screw dome nut on outlet valve

Screw valves onto pump cover

804

803

803

805

803

803

806

803

803

807

803

803

808

803

803

809

803

803

Prototype Base Routing Chart

Pump Base

100 x 70 x 10mm, Aluminium

101

100 Inspect 2 min

2 min Mill to correct dimensions

2 min Drill centre hole

Inspect 1 min

Mill the slots 10 min

16 min Drill four M5 counter bore holes

2 min Inspect/Clean

Mark all centre lines and drill positions

5 min 102

103

104

105

106

107

Prototype Base Routing Sheet Part Name: Pump Base Customer Name: Solo Pump

Australia Ltd Quantity: 1

Stock size: 100 x 10 bar stock Material: Aluminium Length of bar stock: 75mm

Op. #

Process Description

Machine Speed Feed (mm/min)

Tooling Time (min)

Risk Assessment

100 Inspect dimensions of

material

n/a n/a n/a Vernier Calliper,

micrometer

2 Low

101 Mill material to 100 x 70 x 10

Milling machine

320 rpm 50 Face mill, carbide cutter

2 Close fitting clothing, eye protection and no wearing of

accessories that can be caught on spinning machinery

102 Mark all points of interest (i.e.

drill areas)

n/a n/a n/a Centre punch, ruler,

scriber, set square

5 Low

103 Mill out 5mm diameter slots

of 55mm length

Milling machine

16m/min 50 Slot drill 10 Close fitting clothing, eye protection and no wearing of


104 Inspect dimensions of

slots

n/a n/a n/a Telescopic gauges, Vernier Calliper

1 Low

105 Drill 10mm diameter hole in centre of top

face

Drill press

32m/min n/a 10mm drill bit



106 Drill four M5 counter bore

holes

Drill press

16m/min n/a 5.5mm drill bit, 9.0mm flat drill bit



107 Clean/Inspect and file off any sharp edges

n/a n/a n/a Vernier Callipers,

Brush, “Second

cut” file

2 Low

Total Time 40min

Piston

Ø39mm, Aluminium (65mm depth)

20

70

10 Inspect raw material 1 min

10 min Face ends, material, total 64mm height

25 min Turn shaft diameter to 11mm diameter, length 49mm from bottom surface, rough

Inspect 1 min 40

Turn O-ring groove to 1.95mm wide, 36.30 diameter, 6.53mm from the top surface

10 min

Inspect 1 min

30

50

80 5 min Drill 6mm hole 5mm from bottom surface

90 1 min File sharp ends

60 3 min Turn shaft diameter to 10mm

MMAN1130 ROUTING SHEET/ WORK METHOD SHEET Part Name: PISTON FOR PROTYPE Part Number: 2 Drawing No: 2 Revision No: 1 Date: 06/05/2014 Planner: JESSICA

AVEDAWN CHEN Material: Aluminium Stock Size: Ø39mm,65 mm length Comments: None

Operation Number

Description Machine/Tools Tools Speed/Feed (rpm)

Time (min)

Risk Assessment

200 Inspect raw material Vernier Caliper N/A N/A 1 Low 201 Face ends, material,

total 64mm height Centre Lathe

HSS Cutter 575 10 Sharp, high speed cutter and moving parts

202 Turn O-ring groove to 1.95mm wide, 36.30 diameter, 6.53mm from the top surface

Centre Lathe


203 Inspect

Vernier Caliper N/A N/A 1 Low

204 Turn shaft diameter to 11mm diameter, length 49mm from bottom surface, rough

Centre Lathe

HSS Cutter 575, 640, 725, 830, 975, 1185, 1500

25 Sharp, high speed cutter and moving parts

205 Turn shaft diameter to 10mm

Centre Lathe


206 Inspect

Vernier Caliper N/A N/A 1 Low

207 Drill 6mm hole 5mm from bottom surface

Drill Press 6mm HSS Drill Bit 3750 5 High speed movement, sharp drill bit

208 Filing

Hand File Double Cut, Smooth Cut File

N/A 1 Low

TOTAL TIME: 57 min

Aluminium 50mmx50mmx49mm

301

302

306

307

308

300

305

304

303

1 minute

10 minutes

4 minutes

5 minutes

1 minute

10 minutes

15 minutes

1 minute

1 minute

Inspect material

Face top and bottom

Mark out center and points for holes

Drill 39mm hole in center

Check and measure

Drill eight 5mm holes on top and bottom

Tap eight M5 holes on top and bottom

Remove sharp edges and burs

Inspect

Routing sheet Part name: Piston Housing Part number: 3 Drawing number: 3 Stock size:

50mmx50mm Material: Aluminium Quantity: 1 Date: 02/06/14 Revision number: 2 Operation number

Process description

Machine/tool

Feed (m/min)

Speed (RPM)

Tooling Time (min)

Risk assessment

301 Inspect material

Calliper n/a n/a n/a 1 Low

302 Face both top and bottom

Mill 25 200 Face mill 10 Very sharp high speed cutter

303 Mark out centre and holes for 39mm hole and 8 10mm holes

Vernier calliper, magnetic angle plate, scriber

n/a n/a n/a 4 Low

304 Drill 39mm hole in centre

Drill 30 600 39mm twist drill bit

5 Very sharp high speed drill

305 Check and measure

Calliper n/a n/a n/a 1 Low

306 Drill 8 10mm holes on top and bottom

Drill 30 1000 5mm twist drill bit

10 Very sharp high speed cutter

307 Tap 8 M5 holes on top and bottom

Table vise n/a n/a M5 tapping bit, tap handle and set square

15 Low

308 Remove sharp edges and burs

File n/a n/a Second cut 1 Low

309 Inspect Calliper n/a n/a n/a 1 Low Total 53

Prototype Pump Cover

50mm x 50mm x 10mm, Aluminium

Inspect raw material 1 min

5 min Face surfaces

2 min

2 min

Drill and ream holes for 4 housing attachment screws 3 min

Drill hole for outlet tube

2 min

2 min

Tap inlet tube hole

1 min

Tap outlet tube hole

2 min

Drill hole for inlet tube

400

401

402

404

405

407

403

406

Drill holes at base of outlet tube hole

408 Inspect

PROTOTYPE HOUSING ROUTING SHEET

Part Name: Piston Cover Customer Name: Solo Pump Australia Ltd. Quantity: 1

Stock size: 50 x 50mm bar stock Material: Aluminium Length of bar stock: 10mm

Op.

# Process Description Machine Speed Feed (mm/min) Tools, Fixtures Time (min) Risk Assessment

400 INSPECT raw material - - - Vernier Calliper 1 -

401

FACE and SQUARE top and

bottom surfaces to

required dimensions

Turret Mill 300 rpm 240

Face Cutter

(carbide cutter),

Machine Vise

5

Loose clothing, jewellery, long hair/beards can get caught in spinning machinery. Must be confined or close fitting to body. Constant danger of flying particles. Eye protection must be warn.

402

DRILL and REAM 5mm

holes for the 4 housing

attachment screws

Drill Press 16 m/min 200 5mm Drill Bit,

Drill Vise 3


403

DRILL and REAM 10mm

hole for inlet valve

(through entire block)

Drill Press 32 m/min 200 10mm Drill Bit,

Drill Vise 2


404

DRILL and REAM 10mm

hole for outlet valve (until

3mm from bottom of

block)

Drill Press 32 m/min 200 10mm Flat Drill

Bit, Drill Vise 2


405

DRILL and REAM 1.5mm

for the 2 holes at base of

outlet tube

Drill Press 5 m/min 200 1.5mm Drill Bit,

Drill Vise 2

Loose clothing, jewellery, long hair/beards can get caught in spinning machinery. Must be confined or close fitting to body.

Constant danger of flying particles. Eye protection must be warn.

406 TAP M12 for the inlet tube - - -

M12 Tapping Bit

(course), Bench

Vise

2 -

407 TAP M12 for the outlet

tube - - -

M12 Tapping Bit

(course), Bench

Vise

2 -

408 INSPECT holes and thread - - - Vernier Calliper 1 -

- TOTAL 20 -

Outlet valve



2 min Mill to size

3 min Cut O-ring groove

Bore 7.5mm hole 2 min

Drill 6mm hole 2 min

Tap external threads from top 2 min

Inspect/Clean 1 min

2 min Tap external threads from bottom

500

501

502

504

505

503

506

507

Inlet valve



2 min Mill to size

3 min Cut O-ring groove

Bore 7.5mm hole from bottom 2 min

Drill 6mm hole 2 min

Inspect/Clean 1 min


600

601

602

604

605

603

607

Dome nut

M12 x 1.75 Steel Dome Nut

Inspect 1 min

2 min Drill 4 holes

Inspect/Clean 1 min

700

701

702

Part: Outlet Valve

Stock Size: 12mm Dia Material: Aluminium

Length of bar: 35mm

Op. No Description Machine/Tools Speed/Feed Tooling Time (min)

1 Inspect Vernier Calliper 1

2 Cut to size Mill 2000RPM Face mill 2

3 Drill 6mm hole through Drill press 4000 RPM 6mm drill bit 2

4 Bore 7.5mm hole 10mm down from top

Drill press 3200 RPM 7.5mm flat bore ??

2

5 Cut o ring groove Lathe 2800 RPM ?? 3

6 Tap M12 threads on the exterior from bottom

Drill press 1300 mm/min

M12 tapping 2

7 Tap M12 threads on the exterior from top


M12 tapping 2


Table 1: Outlet valve routing sheet

Part: Inlet Valve

Stock Size: 12mm Dia Material: Aluminium

Length of bar: 25mm


9 Inspect Vernier Calliper

10 Cut to size Mill 2000RPM Face mill 2

11 Drill 6mm hole through Drill press 4000 RPM 6mm drill bit 2

12 Bore 7.5mm hole 10mm up from the bottom

Drill press 3200 RPM 7.5mm flat bore ??

2

13 Cut o ring groove Lathe 2800 RPM ?? 3

14 Tap M12 threads on the exterior from bottom


M12 tapping 2


Table 2: Inlet valve routing sheet

Part: Dome Nut

Shelf Component Material: Aluminium

M12x1.75 Dome Nut


16 Inspect Vernier Callipers 1

17 Drill 4 holes Drill press 9500 2.5mm drill bit 3


Table 3: Dome Nut routing sheet

Outlet Valve

12 dia x 35, Aluminium

fig 1: Outlet valve routing chart

20

1 Inspect 1 min

2 min Mill to size


Cut o-ring groove 3 min

Bore 7.5mm hole 2 min

Tap external threads from top 2 min

4

6

1 min Inspect/Clean

Drill 6mm hole 2 min 3

2

5

7

8

Outlet Valve

12 dia x 25, Aluminium

fig 2: Inlet valve routing chart

Dome nut

M12 x 1.75 Steel Dome Nut

fig 3: Dome Nut routing chart

20

9 Inspect 1 min

2 min Mill to size


Cut o-ring groove 3 min

Bore 7.5mm hole from bottom 2 min 12

14

1 min Inspect/Clean

Drill 6mm hole 2 min 11

10

13

15

20

16 Inspect 1 min

2 min Drill 4 Holes

1 min Inspect/Clean

17

18

Appendix B

High Volume

5

50

10

100

70

19

19

10

TOP VIEW

10

9

5

5.50

FRONT VIEW

ISOMETRIC VIEW

AS1100

TITLE


APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.5mm ALUMINIUM

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSWDRAWN BY PUMP BASE

1QTY

J.A. CHEN (Z3461958)FIRST RELEASE DATE

1.6

1/6/143


A. CHUNG (Z3463320)

2/4/14J.A. CHEN (Z3461958)


1

SCALEMATL1:1


R2

R2

R2

6

15

45

A

39

10

ISOMETRIC VIEW

1.9

5 0 0

1.35 -00.05


AS1100

FRONT VIEW

TOP VIEW

TITLE


APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.3mm ALUMINIUM


PISTON

100000QTY

G. CHENG (Z3463228)FIRST RELEASE DATE

1.6

04/06/20141


J. A. CHEN (Z3461958)

06/06/2014G. CHENG (Z3463228)


2

SCALEMATL1:1


49

47

6

A

50

47

43 39

50

8 X M5 10 EQUALLY SPACED R2

6

1.2

0


TOP VIEW

ISOMETRIC VIEW

FRONT VIEW

AS1100

TITLE


APPROVED BY

CHECKED BY

REV DATE

DO NOT SCALE

A40.5mm ALUMINIUM

DRAWN BYHOUSING

100000QTY

ALVIN CHUNG (Z3463320)FIRST RELEASE DATE

1.6

03/06/141


LIZA CHAO(Z3463320)

03/03/14ALVIN CHUNG (Z3463320)


3

SCALEMATL1:1

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING - UNSW


A

50

R26.87

50

4x R2

M12

15

4.2 4 HOLES EQUALLY SPACED

M12 7 MIN LG

45°

ISOMETRIC VIEW

FRONT VIEW

TOP VIEW

AS1100

REV

TITLE

1:1

NOTED OTHERWISE

APPROVED BY

CHECKED BY

DATE

DO NOT SCALE

TOLERANCE UNLESS

A40.5mm ALUMINIUM


PUMP COVER

1

QTY

NADAV COHEN (Z3460696)FIRST RELEASE DATE

MATL SCALE

1.6

06/06/2014

MILLIMETRESDRAWING NUMBER

GAVIN CHENG (Z3463228)

04/04/2014ALVIN CHUNG (Z3463320)

DIMENSION IN NOTED OTHERWISE

4

SURFACE FINISH UNLESS

1

10

4X R2


4

2 X 1.5

SolidWorks Student License Academic Use Only

High Volume Routing Chart

Pump Base

Molten Aluminium

100

100

Die Cast 5 min

2 min Inspect

High Volume Base Routing Sheet Part Name: Pump Base Customer Name: Solo Pump

Australia Ltd Quantity: 100,000

Stock size: Size as casted Material: Aluminium Part Number: 1

Op. #

Process Description


Tooling Time (min)

Risk Assessment

100 Die cast using a pre-made

mold

Cold Chamber Machine

n/a n/a Die cast mold

10 Material of high temperatures are being used therefore

gloves, long sleeve clothing, eye protection must be worn

101 Inspect Optical Compara

tors

n/a n/a n/a 2 Low

Piston

Molten Aluminium

Die Cast Material

10 min

1 min Inspect Die Cast Material

200

201

PISTON ROUTING CHART FOR HIGH VOLUME

202 1 min Turn O-ring groove to 1.95mm wide, 36.30 diameter, 6.53mm from the top surface

201 1 min Clean and Inspect

MMAN1130 ROUTING SHEET/ WORK METHOD SHEET Part Name: PISTON FOR HIGH VOLUME Part Number: 2 Drawing No: 2 Revision No: 1 Date: 03/06/2014 Planner: JESSICA

AVEDAWN CHEN Material: Aluminium Stock Size: As Cast Comments: None

Operation Number

Description Machine/Tools Tools Speed/Feed (rpm)

Time (min)

Risk Assessment

200 Die Cast Material

Cold-Chamber Die Casting Machine

N/A N/A 10 Very hot material

201 Inspect Die Cast Material

N/A N/A N/A 1 Low

202 Turn O-ring groove to 1.95mm wide, 36.30 diameter, 6.53mm from the top surface

Lathe


203 Clean and Inspect

N/A N/A N/A 1 Low

TOTAL TIME: 13 min

Molten aluminium

Part name: Piston Housing high volume

Part number: 3 Drawing number: 3 Stock size: as cast

Material: Aluminium Quantity: 100,000 Date: 02/06/14 Revision number: 1 Operation number

Process description

Machine/tool

Feed (m/min)

Speed (RPM)

Tooling Time (min)

Risk assessment

300 Inspect material

n/a n/a n/a Calliper 1 Low

301 Die-cast a 50mmx50mm square with filleted edges of 2mm. 39mm hole in centre. 4xM5 10mm holes on top and bottom

Cold chamber die machine

n/a n/a n/a 10 Hot molten metal

302 Mark out centre 8x10mm holes

n/a n/a n/a Vernier calliper, magnetic angle plate, scriber

4 Low

303 Tap 8 M5 holes on top and bottom

n/a n/a n/a M5 tapping bit, table vise, T square,

15 Low

304 Inspect Calliper n/a n/a n/a 1 Low Total 31

301

302

300

304

303

1 minute

10 minutes

4 minutes

1 minute

15 minutes

Inspect material

Die casting

Mark out center and points

for holes

Tap eight M5 holes on top and

bottom

Inspect

High Volume Pump Cover

Molten Aluminium

Die cast material 10 min

1 min Inspect casted material

Tap M12 for inlet and outlet valve holes 3 min

1 min

401

400

402

403 Inspect holes and threads

HIGH VOLUME HOUSING ROUTING SHEET

Part Name: Piston Cover Customer Name: Solo Pump Australia Ltd. Quantity: 100,000

Stock size: 50 x 50mm bar stock Material: Aluminium Length of bar stock: 10mm

Op. # Process Description Machine Speed Feed (mm/min) Tools, Fixtures Time (min) Risk Assessment

400 INSPECT casted material - - - Vernier Calliper 1 -

401 REAM all holes to required

dimension Drill Press 5 m/min 200

Drill Bits (5mm,

10mm, 1.5mm),

Drill Vise

4

Loose clothing, jewellery, long hair/beards can get caught in spinning machinery. They must be confined or close fitting to body Constant danger of flying particles. Eye protection must be warn.

402 TAP M12 for the inlet and

outlet valve holes - - -

M12 Tapping Bit

(course), Bench

Vise

3 -

403 INSPECT holes and thread - - - Vernier Calliper 1 -

- TOTAL 9 -


Valve

Molten Aluminium


Cap

Molten Aluminium

501

502

Die Cast 3 min

0.5 min Inspect

601

602

Die Cast 3 min

0.5 min Inspect

High Volume Valve Routing Sheet Part Name: Valve Customer Name: Solo

Pump Australia Ltd Quantity: 200 000


Op. #

Process Description


Tooling Time (min)

Risk Assessment

501 Die cast using a pre-made mould


n/a n/a Die cast mould



502 Inspect Optical Comparators

n/a n/a n/a 0.5 Low

High Volume Valve Routing Sheet Part Name: Cap Customer Name: Solo

Pump Australia Ltd Quantity: 100 000


Op. #

Process Description


Tooling Time (min)

Risk Assessment

601 Die cast using a pre-made mould


n/a n/a Die cast mould



602 Inspect Optical Comparators

n/a n/a n/a 0.5 Low

Appendix C

Solo Pump Australia Ltd 333 Princess Rd

Woodlawn, NSW 2330 Phone 9888 3344

Fax 9888 4433

To: PP175 product development team

FUNCTIONAL SPECIFICATION for the

PP175 Vertical Displacement Pump

must

The University of New South Wales School of Mechanical and Manufacturing Engineering

MMAN1130 Design and Manufacturing

Material List Material Section Material Cost per metre

50.0mm diameter round bar Aluminium $136.67 Steel $83.33



50mm x 50mm square Aluminium $140.00 Steel $122.67

Flat section: 100mm wide x 10mm thick Aluminium $56.00

Steel $47.33

design and manufacturing mman1130 final report · 4.1.10 conclusion ... the purpose of this report...

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