Reproduction of Tractor Components Senior Design Project Spring ‘07 Charlie Tullis.

Reproduction of Tractor Reproduction of Tractor ComponentsComponents

Senior Design Project Spring ‘07 Charlie Tullis

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

1914 McCormick 8-16 1914 McCormick 8-16 Mogul TractorMogul Tractor Problem: Customer Problem: Customer

missing partmissing part

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

Original International Original International Harvester Corp. Final Harvester Corp. Final Part printsPart prints

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage Predicted PorosityPredicted Porosity

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

Manufacturing Plan

Part Exhaust Head

Process

Sub- Processes Location Tools

Core making      

Filling Core wash repair Foundry Core Boxes Sand Mixer daub paste wash

Molding      

Molding Mold washing Coring Closing Foundry Patterns Wash Files Paste Chaplets Clamps/Weights

Pouring   Foundry  

Cleaning/ Inspection  

Foundry/Out Source Sand Blaster Grinders Paint Equip.

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

MetallurgyMetallurgy Total Carbon Total Carbon =3.57%=3.57% SiliconSilicon =3.37%=3.37% Cu Cu =?=? CrCr =.02%=.02% MoMo =.01%=.01% PP =.89%=.89%

Desired Brinell Hardness HB=170-200

Actual HB= 321

Part #One: Exhaust Valve CagePart #One: Exhaust Valve Cage

Grey Iron

80% type A graphite

20% type D&E

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CageMoldingMolding

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CageMoldingMolding

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CagePouring Pouring

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CagePouringPouring

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CageShake OutShake Out

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CageCleaned PartsCleaned Parts

Part #One: Exhaust Valve CagePart #One: Exhaust Valve CageCasting DefectsCasting Defects

Gas defect only ( Blow)Gas defect only ( Blow)

Part #Two: Intake/Exhaust Part #Two: Intake/Exhaust ManifoldManifold

Part #Two: Intake/Exhaust Part #Two: Intake/Exhaust ManifoldManifold

Manufacturing Plan

Part Intake/Exhaust Manifold

Process Sub- Processes Location Tools

Core making      

 Filling Assembly Core wash repair Foundry

Core Boxes Sand Mixer daub paste wash

Molding      

Molding Mold washing Coring Closing Foundry

Patterns Wash Files Paste Chaplets Clamps/Weights

Pouring   Foundry  

Cleaning/ Inspection   Foundry/Out SourceSand Blaster Grinders Paint Equip.

Part #Two: Intake/Exhaust ManifoldPart #Two: Intake/Exhaust Manifold

MetallurgyMetallurgy CC =3.66%=3.66%Si Si =1.6%=1.6%Ni Ni =0.9%=0.9%CrCr =0.85%=0.85%MoMo =0.65%=0.65%Cu Cu =0.35%=0.35%

Part #Two: Intake/Exhaust ManifoldPart #Two: Intake/Exhaust Manifold

Original ManifoldOriginal Manifold Manifold PatternManifold Pattern Follow Board Follow Board

Part #Two: Intake/Exhaust ManifoldPart #Two: Intake/Exhaust Manifold

Exhaust Core Boxes ( under construction)Exhaust Core Boxes ( under construction)

Part #Two: Intake/Exhaust ManifoldPart #Two: Intake/Exhaust Manifold

Intake Core blankIntake Core blank

Part #Two: Intake/Exhaust ManifoldPart #Two: Intake/Exhaust Manifold

Pin Core BoxPin Core Box

Inspection ProcessInspection Process

Solid wallsSolid walls InclusionsInclusions Surface defects Surface defects

(rat tails, (rat tails, buckles, burn buckles, burn on)on)

Pin holesPin holes Cold lapsCold laps

Inspection tools

Visual

Pressure test

Ultrasonic imaging

BudgetBudget

ScheduleSchedule