HARTWELL CORPORATION UC IRVINE MAE 188 Engineering Design Industry Flush Handle Latch Assembly Redesign Students Faculty A dvisors H artw ellC orp. Engineers Jerem y K im K evin W en Phong D iep Y uk M ing W ong D erek D unn-Rankin H arisJ. Catrakis J. M ichaelM cCarthy Frank T. Jackson John F. G illen Tim Rozem a
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HARTWELL CORPORATION UC IRVINE MAE 188 Engineering Design Industry Flush Handle Latch Assembly Redesign.
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HARTWELL CORPORATIONUC IRVINE
MAE 188Engineering Design Industry
Flush Handle Latch Assembly Redesign
Students Faculty Advisors Hartwell Corp. Engineers
Jeremy KimKevin WenPhong DiepYuk Ming Wong
Derek Dunn-RankinHaris J. CatrakisJ. Michael McCarthy
Frank T. JacksonJohn F. GillenTim Rozema
Goal Statement
• Redesign the H3414-33 flush handle latch assembly to reduce its manufacturing cost and improve its wearability.
Flush Handle Latch Assembly H3414-33
•H3414-33 has 92 parts per assembly •Customers
– Canadair – Bombardier
Specifications
Metric Marginal Ideal
Cost $ each forquantity of 100
Less than current(< $1302.46)
20% less($1041.97)
Plating usage # parts 50% less None
Durability Cycle/return 30,000 300,000
Functionality Qualitative Same Same
Externalgeometry
Qualitative Same Same
Weight Lbs 20% less(5.4)
50% less(3.3)
Temperaturerange
°F -50 to 200 -80 to 300
• Cost Analysis – Cost analysis is based on Cost Auditor
Quote with quantity of 100
– Total manufacturing cost = $1,302.46
– Labor cost includes overhead rate factor of 4.03 (burdened labor)
– 4 categories of manufacturing cost• Burdened Labor
• Material
• Outside Processing
• Purchase Each
Total Manufacturing Cost Breakdown 02/05/01
B Labor52.13%
MATL34.07%
O/P6.80%
PurEa6.99%
ASSEMBLY NUMBER : H3414-33 QTY: 100 RCVD DATE :Rev :
DESCRIPTION: NOTES: Total Manufacturing Cost(TMC)
Hours ** Direct Cost **
Itm PART NO. DESCRIPTION QTY TYPE S/U Ea. Pc RATE LABOR B Labor %TMC MATL %TMC O/P PurEa Mfg Cost
– Compression Molding• Requires plastic as material
• Cost of Process– Tooling cost
– Raw material cost
Casting Machining Forging Plating Surface Finishing Precision Inspection132796-1 (handle) X X X X X117052-999 (housing) X X X X119922-997 (actuator) X X X X117067-999 (collar) X X X X
Machining• Current Sequence
– setting fixture setting tooling checking programs inserting casted parts remove finished parts inspection storage
• Alternatives– net-shape forming
Advantages Disadvantages virtually no material waste lower energy product because material
is Mold parts into high-precision finished parts diluted by the binding polymer lower manufacturing cost by saving machining decreased corrosion resistance time lack of high quality, reasonable-cost power Ideal for complex shapes price for general alloys average $40/pound
– outside processing (O/P) in foreign countries Outside processing in foreign countries has several disadvantages: present currency exchange rate between Europe and America limits the benefits complexity of certain parts makes O/P impossible. Reliability and quality control becomes a problem. instability of foreign work force – machining optimization
install software to provide a better integrated CNC production facility change tooling and carbide brand and type install high pressure coolant systems to increase production efficiency and extand tool life time
Functional Design
• Existing– A spring-loaded release lever that
extends and rotates the outside handle assembly from inside the door.
– A spring-loaded outside handle assembly that seats flush in the housing when stowed for flight, and extends under spring load for use when the trigger or release lever is pushed.
– The flush handle latch assembly consists of one each: release lever, rod end, cover, actuator rod (not shown), outside handle assembly with integral spring-loaded trigger, trigger lift assembly actuator fitting, inner support, and a collar.
– Components are secured by attaching hardware and pins retained by sealant.
– Elastomer quad rings in the actuator assembly, inner support, and collar provide environmental and pressure seals.
601R38132-11, 601R38132-13Nomenclature Flush Handle Latch AssemblyFUNCTIONAL CHARACTERISTICSHandle Travel 44 to 46 Degrees (counterclockwise)Outside Handle Extension to Operating Position 1.45 to 1.55 in. (36,83 to 39,37 mm)Torque Required to Turn Handle 10 in-lbs (1,13 N.m) maximum at 55 to 75*F (13 to 24*C)Force Required to Stow Outside Handle 15 lbs (6,8 kg) maximumPressure Difference Without Leakage 18.5 psig (123 kPag) maximumPHYSICAL CHARACTERISTICSOverall DimensionsHeight 8.81 in. (223,77 mm)Width 7.57 to 7.87 in. (192,28 to 199,89 mm)Length 15.17 to 15.28 in. (385,32 to 388,11 mm)Weight 6.6 lbs (3,0 kg) maximum
Functional Design
• Alternatives– fewer parts
– simplified assembly
– new materials
– new manufacturing processes
• Testing
• Wearability
Design Concepts
1. Materials
2. Manufacturing
3. Machining Optimizations
4. Functional Design
Design Concept 1 Materials
• Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced instead of aluminum alloy for collar and flush handle housing
Integrated machining system for production facility from GE Fanuc VisualDocs - Designed to replace paper and improve productivity on the shop floor, this software can provide operators with access to virtually any information on the floor, helping them tap into the combined operating knowledge of the company. VisualMEM - Designed to help manufacturers gather machine performance information on the floor, VisualMEM (Machine Event Monitoring) records each event that takes place on a machine and places that information in a database for further analysis. 10% production improvement typical when implemented. VisualDocs
Visual MEM
Machining optimization: hardware
change tooling and insert type or brand
For the machining of 17-4 PH stainless steel and A356.0 T61 Al alloy, two alternative
tooling inserts from Kennametal are suggested:
For 17-4 PH stainless steel For A356.0 T61 Al
alloy
insert geometry: MM-MR MS
recommended Grade: KC9025 KD100
feed rate: 0.0255 in 0.0186 in
depth of cut: 0.2102 in 0.1046 in
install EV2000 high pressure coolant system produced by chipblaster (unit price: $15,695)
machining time and tool life time will increase 30% minimum
cost saving study: - 8.477 hrs of machining labor per piece under regular coolant system
- overhead rate of 4.03
- assume an average labor rate of $15.00/hr
- assume 30% production efficiency and tooling life gain by using high
pressure coolant system
(8.477*15*4.03) - (8.477*.70*15*4.03) = 153.73 ----------------------------- cost saving per piece
15,695 / 153.73 = 102.09------------------------------ pay back after 103 units
153.73*100 = 15,373------------------------------ machining labor saving per