carter construction

[eldiablo]

Hello, everyone. I and a colleague of mine have designed a two-stage aircraft epicycloidal reducer for a university project. After finishing the design and sizing phase, we were assigned two details to be listed and for which to define all the production process. one of these is the semicarter-1, visible in the pdf enclosed by me. According to an experienced user, the best process to get this piece is the polycast fusion, as a processing to the only machine tools would result in excessive waste of material. to this would follow the sandblasting of the inner surface to increase the heat exchange with the oil, a turning/rectification for the bearing seats and sealing ring, realization of all the holes with only oil duct aleration (and possible rectification of the surfaces to be connected???). do you recommend me such a solution? in particular:
1) is polycast actually the best way to get the piece?
2) in the case of polycast, better to make each model of polystyrene to machine tools or to make two aluminum molds, to obtain for molding each semi-model, to couple it with the other half adding casting channel, etc...?
3) Are there other jobs to be done later?
4) for the holes of the reference thorns, first I collect the parts and then pierce all the pieces together?
production is 200 pieces per year for 20 years and the piece is made of magnesium alloy.
I thank you in advance for your help.

 

[SHIREN]

Hello, everyone. I and a colleague of mine have designed a two-stage aircraft epicycloidal reducer for a university project. After finishing the design and sizing phase, we were assigned two details to be listed and for which to define all the production process. one of these is the semicarter-1, visible in the pdf enclosed by me. According to an experienced user, the best process to get this piece is the polycast fusion, as a processing to the only machine tools would result in excessive waste of material. to this would follow the sandblasting of the inner surface to increase the heat exchange with the oil, a turning/rectification for the bearing seats and sealing ring, realization of all the holes with only oil duct aleration (and possible rectification of the surfaces to be connected???). do you recommend me such a solution? in particular:
1) is polycast actually the best way to get the piece?
2) in the case of polycast, better to make each model of polystyrene to machine tools or to make two aluminum molds, to obtain for molding each semi-model, to couple it with the other half adding casting channel, etc...?
3) Are there other jobs to be done later?
4) for the holes of the reference thorns, first I collect the parts and then pierce all the pieces together?
production is 200 pieces per year for 20 years and the piece is made of magnesium alloy.
I thank you in advance for your help.

Hi.
to a very first analysis you have to build 3 models with relative chests
for n° 200 fusions year we can think of making them also in resin
the prob. in the possible it is to eliminate the soul cases
you should attach the individual components to the table with its sez
with indications of working areas

then decide which fusory technology to apply
Thank you

 

[meccanicamg]

I answer you for the mechanical machining part.
Spinning could be done directly on semicarters with decent tool machines.
It is also true that for the speech regulation games you could have a pre-light and then drill and alear to the assembly.
I would say that for how it was thought you can already do the holes in h7 when friezes and holes the travases.

for the foundry part it would be good that shiren responded.
I argue that the polycast is cleaner and for 200 pcs/year can go well. making the wooden model more or less composed according to me can go well under 10 pieces more or less.

for the preparation of the model I would say that if you make the polystyrene you have to paint it specially.
even the wax system to lose could be used... but I don't get excited.

 

[SHIREN]

I answer you for the mechanical machining part.
Spinning could be done directly on semicarters with decent tool machines.
.

hello mechanicalng
the pieces are not semi-carter but melted more or less round with outer sunshades
that at least on one side of each single carter should also be eliminated to insert captive screws
therefore every single element can or could be worked on lathe
where you would echo the pavement and analyzing for bearings and trees etc etc.

I answer you for the mechanical machining part.

I would say that for how it was thought you can already do the holes in h7 when friezes and holes the travases.

.

for how everything was thought
I think we have to consider the most real hypothesis of redesigning everything
industrializing the product
appropriate processing angles
establish the model's seat
think of eliminating the souls in the possible

I answer you for the mechanical machining part.
Spinning could be done directly on semicarters with decent tool machines.
It is also true that for the speech regulation games you could have a pre-light and then drill and alear to the assembly.
I would say that for how it was thought you can already do the holes in h7 when friezes and holes the travases.

for the foundry part it would be good that shiren responded.
I argue that the polycast is cleaner and for 200 pcs/year can go well. making the wooden model more or less composed according to me can go well under 10 pieces more or less.
.

for a wooden modeling you can also go to 200 pieces/year
considering a fixed maintenance cost
models should be made in ureol (resine) either in slabs or even casting
aluminium (dimensional stability over time) must multiply the costs of the equipment x 4 (four)

I answer you for the mechanical machining part.


for the preparation of the model I would say that if you make the polystyrene you have to paint it specially.
even the wax system to lose could be used... but I don't get excited.

for polystyrene models you can only make a fusion as a prototype
adding an exaggerated overmetal plus +10mm/route
with wax to lose we do little
Thank you

 

[eldiablo]

I have performed the quotation of the piece. Hopefully it's correct, I think it might be helpful to understand how and what to do to produce it.

 

[SHIREN]

I have performed the quotation of the piece. Hopefully it's correct, I think it might be helpful to understand how and what to do to produce it.

Hi.
the quotation of the table I think you made it a moment with too much superficiality
or at least you did something fast
Anyway, I'll tie you a sketch.
where the model's seat is indicated
with its machining overmetal
model in nature with plaque drowning
we avoid the soul cases
I also deleted n° eight(8) perimeter studs on one side
adding extruded meatballs to the body
all the crude has angles of 2nd leaf to increase
if you tell us exactly the type of material
I give you the value of the metal collection to be added to the model
remain waiting for your evaluation
Thank you very much

 

[eldiablo]

shiren are impressed by its efficiency and speed. However, it is necessary for you to explain some things to me because my (im)preparation with respect to your experience in this area is really impallic.
the material is an ultralight alloy for 9 mg jets, however we chose it quite "in case". If she had some better magnesium alloy, change is possible. Consider that the carter must bear such negligible stresses that the professor did not even ask that we verify it with the fem model. operating temperatures are on the order of 110°C

 

[meccanicamg]

already with 110 degrees centigrade...the nbr gaskets you can't mount...you have to use viton.

 

[SHIREN]

shiren are impressed by its efficiency and speed. However, it is necessary for you to explain some things to me because my (im)preparation with respect to your experience in this area is really impallic.

Thank you.

shiren
the material is an ultralight alloy for 9 mg jets, however we chose it quite "in case". If she had some better magnesium alloy, change is possible. Consider that the carter must bear such negligible stresses that the professor did not even ask that we verify it with the fem model. operating temperatures are on the order of 110°C

we are at a school or educational level
I understand that we should look good at colleagues and professors.
but I have always asked in other similar discussions
that teachers or prof. indicated a budget(€) more or less real
it is too easy to indicate products and materials and technologies
when you are not forced to deal with economic resources
the model I have attached a simple sketch
can cost from 500€ up to 5k-6k
in both cases work we do the same
the materials we can use the best alloy at a price of 100€ per kg
but we can also use alloys at 10€ per kg
the carter we do the same
and obvious that in the specific discussion
we have no competition
we have no other producers who impose their price
unbalanced can urge other comments or criticisms
of which we gladly do not

p.s.
your reducer is composed of other fuses
if you adopt my directions you should draw the whole again and at the end


Thank you very much

 

[meccanicamg]

shiren....the teachers especially in these years, have an inadequate preparation and above all have never worked on the field. therefore sti poor students find themselves to slam their heads against the wall and if we do not help them that we are professionals, they must only use the fantasy by copying from the book of mechanical technology.

definitely should be reviewed the design of the carter to adapt to the characteristics of the methods of fusion.

with the indications of shiren I would say that you can remodel the carter at least for the corners of sform and the meatballs.
the rest we try to make it go well.
for the leagues, I would say that what costs... not being there a fixed budget... just speculates.

 

[eldiablo]

What you say is obviously just right. the function to optimize in the project is obviously the cost, so the less you can spend to do something better is, if two materials can fulfill the same task I will choose the cheapest one, etc..
However, we have chosen an aircraft-type reducer to be able to "until" us from this restriction: do two extra jobs and spend more money and time in construction and assembly can be compensated by the fuel saving that you have in carrying back for 20 years of service a assembly that weighs 45 kg instead of 50kg. It is obvious that the speech is very complicated and that it is not always easy to evaluate pro/contro, especially in economic terms and especially for a student who only studied books and that on the work has seen at most some videos on youtube.
for this return to the original speech: we have a component to build. The important thing is that it is realized with methodologies that make sense and that they can convince someone else that they are the best among those possible.
That said, the model she made seems to me great: the "side bags" on the wide diameter we could also think of getting them later to the milling machine, while a turning as indicated in the figure would return the original design. I also modify the original piece by adding 4 degree angles inside
for mechanicsmg: the manufacturer certifies the seals in nbr up to 120°c; according to his advice I decided to replace those of the slow trees with the corresponding silicone, guaranteed up to 170°c. the fkm of the solar shaft seal rings (15000rpm), however, are certified up to 40m/s and 220°c.

 

[eldiablo]

obviously angles of stripes.. .

 

[eldiablo]

Looking well at the model, as she had already said before, I would be forced to use captive screws and change the shape slightly. and if we did the model like this?

 

[SHIREN]

shiren....the teachers especially in these years, have an inadequate preparation and above all have never worked on the field. therefore sti poor students find themselves to slam their heads against the wall and if we do not help them that we are professionals, they must only use the fantasy by copying from the book of mechanical technology.

definitely should be reviewed the design of the carter to adapt to the characteristics of the methods of fusion.

with the indications of shiren I would say that you can remodel the carter at least for the corners of sform and the meatballs.
the rest we try to make it go well.
for the leagues, I would say that what costs... not being there a fixed budget... just speculates.

[MENTION=21735]Mechanical[/MENTION]Hi.
once we did a group jobhttp://www.cad3d.it/forum1/threads/5189-progettiamo-per-partecipare-al-concorso-rotational-designunfortunately I have little time available
a few hours in the evening
if someone has time and a moment of passion to dedicate
we could redesign everything
the whole
Let's see how many users would help us
Thank you very much

 

[SHIREN]

Looking well at the model, as she had already said before, I would be forced to use captive screws and change the shape slightly. and if we did the model like this?

Hello eldiablo
what I proposed to you is the standard
in the current socio-economic moment
I could also find a solution to get the castings according to your primary designs
we get it all in soul boxes and solve the prob
but are solutions that were made in the years 60-70-80
when the hand of work cost when the hand of work costs today to the east of the world
Your last proposal
We could do it no prob.
but we have to take into account a large diversity of thicknesses that in alumina for aerospace use
is not granted in truth even thought
In areas with larger thicknesses in the melting phase, it is necessary to add coolers and a series of huge castings
We create a series of probes. that in the current phase I think I avoid

Let us know
Thank you very much

 

[eldiablo]

Can't you change the thicknesses to avoid certain problems without the design being upset?

 

[SHIREN]

Can't you change the thicknesses to avoid certain problems without the design being upset?

Hi.
is common practice to rely on the moulder or modeler
to solve the prob
i.e. 99% of cases in everyday reality
the thing solves the model
at the end of the route
you will be forced to change everything because you will have the fuses as the modeler decides
not according to your drawings
I realize the work to be done
even if according to my humble opinion
in 2-3 hours solve the prob
Thank you very much

 

[eldiablo]

Like something like that, why wouldn't it be okay?

 

[SHIREN]

Like something like that, why wouldn't it be okay?

if you do not want to change the designs
must be built in circular outer body
and get your primary design
the interior always go in nature or with drowning in plaque
Thank you very much

 

[eldiablo]

if I make the resin mold, its mold of what material do it? I work on machine tools? and for the chests of souls?