Large Scale Manufacturing

1
Large Scale Manufacturing
20 March 2007

• John Bannon
• Brian Lagoe
• Eric McDermott
• Kevin Moonan
• Matt Renninger

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Introduction

• Kevin Moonan Project Shop Innovation
• Brian Lagoe Spacecraft Manufacturing
• Matt Renninger Dragline Manufacturing
• Eric McDermott LasershotSM and Casting
• John 7 Bannon Explosive Forming

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Project Shop Innovation

• Kevin Moonan

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Project Shop

• Characterized by the immobility of the item being
  manufactured
• Workers, machines, and materials must come to
  manufacturing site fed by flow shops.
• Small lot sizes due to size of objects
• Airplanes, ships, locomotives, etc.

Photo courtesy of http//www.nerdylorrin.net/jerr
y/politics/Boeing/BoeingScandal.html
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Project Shop Innovation

• Now there are no more monuments on the assembly
  floor.
• Factory tooling and machines are no longer fixed
• SURF Sequential Universal Rail Fixture
• Decreased reliance on overhead cranes

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Automated Assembly Innovation

• Northrop Grumman F-35 JSF airframe assembly
• Automated burr-less drilling
• Structural flexible robotic drilling
• Automated fastening
• Automated part loading

Picture courtesy of http//www.royal-navy.mod.uk/
server/show/ConMediaFile.14276
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Modern Large Scale Manufacturing

• Airbus A380 Assembly Process
• Logistics
• Built throughout Europe Wales, Germany, Spain,
  France
• Custom infrastructure created to support
  transportation ships, barges, and road
  trailers.
• State-of-the-art manufacturing facilities built
  throughout Europe
• Highly automated, innovative manufacturing
  process

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Spacecraft Manufacturing

• Brian Lagoe

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Spacecraft Manufacturing (NASA)

• Low quantity
• Specialty parts
• large sizes
• high performance materials
• Assembly challenges
• Earth weight and size
• Space environment

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Exotic Materials Aerogel

• Hologram appearance
• SiO2 solvent
• 99.8 air
• Low thermal conductivity, high strength to weight
• Uses
• Insulation
• To collect high speed comet dust particles
• Cost 1.00 / cm3

http//stardust.jpl.nasa.gov/tech/aerogel.html
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Assembly (Altimeter)

• Component parts contracted out
• Final assembly and testing at space center
• Clean room assembly floor

Laser Altimeter System for Earth
Observation http//glas.gsfc.nasa.gov/
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Suction Fixturing

• Dedicated fixtures
• Pivoting suction cups
• Used to lift 28 ft mirrors in large telescope
  manufacturing

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Flexible Fixturing

• Pogo System grid work of adjustable pneumatic
  actuators to support large, contoured parts
• loaded up to 800 lbs each, 100s of actuators
• Swivel suction cups
• 50 lb vacuum
• Reverse flow to float the part for positioning
• four stroke lengths-17, 23, 29, and 35
• Position accuracy to 0.003
• Individually controlled by CAD/CAM program

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Crawler Transporter

• 6 million lbs
• 114 ft long
• Driven by two 2750 hp engines
• 1 mph loaded
• 150 gallons of diesel oil / mile

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Dragline Manufacturing

• Matt Renninger

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Bucyrus Dragline

• Used for large scale excavation and mining
• Bucyrus 8750 Walking Dragline
• Weighs excess of 16,000,000 pounds
• Bucket can hold 165 cubic yards of material
• Capable of moving 340,000 kg of material
• Boom length of 430 feet

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Dragline Manufacturing
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Gear Cutting

• MAAG gear cutters capable of cutting gears up to
  14 meters in diameter.
• For large gears, vertical broach is used to cut
  the gear teeth.
• Vertical broach carries a single tooth cutter
  and cuts one tooth at a time progressively
• Vertical broach can utilize extremely tall
  stroke
• Many exceed the limitations of factory ceilings
• Those exceeding 20 feet generally require a pit
  to be dug for the machine

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• Vertical broach with an 18 foot travel

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Gear Cutting

• Over 100 hours to cut the teeth of their largest
  spur gears
• Finishing work must be conducted following
  broaching
• Each gear must be hand ground to remove burrs
  left at the exit side of the broach
• Advantages
• Provides clean, repeatable cut
• Tolerances can be held to ?0.001 inches
• Capable of low cycle times
• Disadvantages
• Separate broach is required for each gear size
• Tooling costs can be very high

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Dragline Manufacturing

• Components are manufactured and assembled at
  various locations
• Largest components produced at project shops
• Components are transported to job site
• Final assembly of individual components takes
  place at the job site
• Manufacturing of all components takes excess of 2
  years
• Final assembly takes up to a year
• Bucyrus manufactures to meet projected sales,
  does not wait for orders

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LasershotSM Precision Metal Forming

• Eric McDermott

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LasershotSM Precision Metal Forming

• Retains structural properties over 2cm thick
• Create greater curvature and smoothness
• Reduced secondary processes

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LasershotSM Precision Metal Forming

• Laser emits 6 pulses per second through 1mm of
  water.
• The water protects from scarring or melting,
  maintaining surface quality.
• Pressure wave travels 5 to 10 times deeper than
  traditional shot peening.
• The laser beam is scanned over the metal to
  create varying curvatures in the part.

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LasershotSM Precision Metal Forming

• Tight curvatures can be created in 2cm parts
  that would be impossible by taditional methods.
• Bombarding parts with the laser also increase
  service life.

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Vacuum Casting

• The mold is composed of a dry, fine silica sand
• Vacuum is maintained in the mold to eliminate
  surface defects which allow for superior part
  finish
• The metal is poured into a tightly assembled
  cope and drag
• Near net shape castings are produced
• Vacuum allows sharp corners, tight radii and
  intricate details

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Air Set Casting

• The Air Set Molding process is used for
  extremely large castings with highly complex
  geometries.
• Molds are comprised of chemically bonded dry
  sand and are suitable for complex shapes with
  multiple center sections.

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Explosive Forming

• John Bannon

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Explosive Forming of Large Plates

• Used to improve the effectiveness of combat
  vehicle armor
• Most notably in tank turrets
• Reduces number of weldments as well as allowing
  for complex curves and depressions to improve
  ballistic protection

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Description of Process

• A sheet of one of various metals is clamped to a
  die
• A charge of proper weight and distribution is
  positioned at standoff distance above die
• Entire setup is submerged into water
• Charge is then detonated while air is
  simultaneously evacuated from the die
• Current processes require 2 or 3 detonations

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Computer Mapping of Deformation After Consecutive
Detonations
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Variables

• Die design and blank size
• Amount of clamping pressure
• Explosive charge parameters
• type
• amount
• shape
• stand-off distance

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Formability of Different Materials by Explosive
Forming
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Advantages

• Process is not limited by any size or thickness
• Capital investment is low, no machinery required
• Close tolerances reproducibility are maintained
• Costly welded assemblies are eliminated by this
  process
• Amount of spring-back is reduced compared to
  conventional forming methods

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Details

• Castings made of kirksite (very dense aluminum
  and zinc alloy)
• Common forming pit size 25ft diameter, 15 ft deep
  water pit with 10-80 ton gantry crane installed
  above
• Gelex 2 is most popular explosive used
• detonation velocity of 12000 ft/sec
• Post blast, material being deformed has slightly
  lower yield and ultimate strength

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Examples
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Questions?