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Reproduction of Tractor Components Senior Design Project Spring ‘07 Charlie Tullis
Part #One: Exhaust Valve Cage 1914 McCormick 8-16 Mogul Tractor Problem: Customer missing part
Part #One: Exhaust Valve Cage Original International Harvester Corp. Final Part prints
Part #One: Exhaust Valve Cage
Part #One: Exhaust Valve Cage Manufacturing Plan PartExhaust Head Process Sub- Processe s LocationTools Core making Filling Core wash repairFoundryCore Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring ClosingFoundryPatterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Ou t SourceSand Blaster Grinders Paint Equip.
Part #One: Exhaust Valve Cage Metallurgy Total Carbon =3.57% Silicon=3.37% Cu =? Cr=.02% Mo=.01% P=.89% Desired Brinell Hardness HB=170- 200 Actual HB= 321
Part #One: Exhaust Valve Cage Grey Iron 80% type A graphite 20% type D&E
Part #One: Exhaust Valve Cage Molding
Part #One: Exhaust Valve Cage Pouring
Part #One: Exhaust Valve Cage Shake Out
Part #One: Exhaust Valve Cage Cleaned Parts
Part #One: Exhaust Valve Cage Casting Defects Gas defect only ( Blow) Gas defect only ( Blow)
Part #Two: Intake/Exhaust Manifold
Manufacturing Plan PartIntake/Exhaust Manifold Process Sub- Processes LocationTools Core making Filling Assembly Core wash repairFoundry Core Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring ClosingFoundry Patterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Out Source Sand Blaster Grinders Paint Equip.
Part #Two: Intake/Exhaust Manifold Metallurgy C=3.66% Si =1.6% Ni =0.9% Cr=0.85% Mo=0.65% Cu =0.35%
Part #Two: Intake/Exhaust Manifold Original Manifold Manifold Pattern Follow Board
Part #Two: Intake/Exhaust Manifold Exhaust Core Boxes ( under construction)
Part #Two: Intake/Exhaust Manifold Intake Core blank
Part #Two: Intake/Exhaust Manifold Pin Core Box
Inspection Process Solid walls Inclusions Surface defects (rat tails, buckles, burn on) Pin holes Cold laps Inspection tools Visual Pressure test Ultrasonic imaging
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MAGNA M a g n a D i g i t e c h I n d i a P r i v a t e L i m i t e d PROBLEM SOLVING OLD METHOD Component Name: Gear Stay Component weight: 182Kgs Number.
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The problem. The problem was that the router had a “Dremel” unit fitted, which was OK for small work, but to use a larger router tip, I would need a larger.
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