B.

ENG(Hons) MECHANICAL ENGINEERING In collaboration with

University of Sunderland

ASSIGNMENT
DESIGN FOR MANUFACTURE SUBJECT CODE: EAT 206 Level 2

LECTURER STUDENT

: MR. FONG WH : CHEEN WENG HOONG (SCSJ 0003047 / UOS - 109079253) : CHANG SAU SEN ( : MATTHEW CHEW ZHI MING ( : TAN WEI KHIN (SCSJ 0004704 / UOS 089104758) : CHONG GHEENG FOO (SCSJ 0009407 / UOS 109079301) : TAN YEN XIANG (SCSJ 0009428 / UOS 109098151) : Car Water Pump Cost Reduction Exercise

TITLE

Introduction
Water pumps are impeller pump, they are attach to the front of the engine and also driven by a belt from the crankshaft pulley. The pump circulates 28,000 litre of coolant an hour. As the impeller rotates the curved blades draw coolant from the bottom of the radiator and force the coolant through the pump outlet to the water jackets. The impeller shaft is supported on sealed bearings which never past the bearings. The water pump is driven by the fan belt. The water pump may also be driven by a single belt that also drives other components. In some engines the water pumps are gear-driven from the engine crankshaft. The purpose of the water pumps are to pump the coolant to parts of the engines, it is to cool down the engines and also to maintain the temperature at a safe limit. Over heating will lead unwanted accidents.

Objective
The objective of this assignment is to find a better design for the water pump. Improvise the current design. Besides just designing, we must also state what are the benefits of it? In terms of cost, labour, method of manufacturing and so on. The performance of the water pump must be compared between the improved design and the existing design in order to know that the changes are needed. Besides that the purpose of this assignment is also to practices our skill to use the software Autodesk Inventor Professional.

Chapter 3: Existing product design

Chapter 3.1: Table

Component Water pump casing
Pulley hub

Quantity Materials 1
1

Manufacturers technology Sand cast

Sand cast

Cast iron
Cast iron

Bearing Gasket 1 Gasket 2 Impeller lock

1 1 1 1

Carbon steel Rubber Rubber Carbon steel

By supplier Stamping Stamping By supplier

Impeller

Steel paint)

(anti

rust Forging and cutting

Oil seal 1 Oil seal 2 Shaft Water seal Water pump cover
Bolt

1 1 1 1 1
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Carbon steel Carbon steel Carbon steel Carbon steel Carbon steel
Steel

By supplier By supplier Casting By supplier By supplier By supplier

Chapter 3.2: Method of Manufacture

For water pump casing and pulley hub a molten metal is poured into a mold or cavity that approximates the shape of the finish part (figure 1). Heat is extracted through the mold, and the molten metal solidifies into the final solid shape. The functions for the mold are: To provide an entry for the molten metal into the mold that creates laminar flow through the sprue and runner. To provide a source of molten metal, suitably located in the mold so that it stays molten until all of the casting has been filled. And the cores are suitably placed to provide hollow features for the part.

Figure 1: parts of a conventional sand casting process.

For gasket The cold stamping of a sheet of rubber with dies can be classified as either a cutting .cutting operation are to punch holes in sheets or to separate entire parts from sheets by blanking. A blanked shape may be either a finished part or the first stage in a forming operation in which the final shape is created by plastic deformation.

The sheared edge that is produced when sheet metal is punched or blanked is neither perfectly smooth nor perpendicular to the sheet surface. Simple blank contours should be used whenever possible since the die cost depends upon the length and the intricacy of the contour of the blank. It may be less expensive to construct a component from several simple parts than to make an intricate blanked part. Blanks with sharp corners are expensive to produce, the layout of the blanks on the sheet should be such as to minimize scrap loss.

Notch a blank along one edge results in an unbalanced force that makes it difficult to control dimensions as accurately as with blanking around the entire contour. The usual tolerances on blanked parts are 0.003in.

Impeller Using the forging process which is typical of a group of bulk deformation processes in which a solid billet is forced under high pressure by the use of a press to undergo extensive plastic deformation into a final near-to-finished shape. After this operation is the cutting which in the machining process. The machining process is required for the drilled holes and finishing.

Assembly for the impeller, impeller lock, oil seals and pulley hub onto a shaft Use the shaft which is manufactured by sand cast as the first step of the assembly process. Then, use the impeller lock fit for assemble the ball bearing onto the shaft. After that, place bushing in oil seal. Into the fourth step, assemble the shaft into the oil seal by knocking and champing. After this, install the oil seal together with the spring onto the shaft by knocking and clamping under a high pressure machine. Install the pulley hub onto the shaft by impeller lock fit as the sixth step. At last step, install the impeller and knocking with the water pump cover into the shaft.

Chapter 3.3: Method of Assemble and Comment

Generally, the main assembly is assembled within water pump casing by applying the bearing parts upon one end of the shaft, inserting the shaft and bearing into one end of the housing, and then applying the oil seal and the impeller, upon the opposite portions of the shaft and into the opposite end of the water pump casing.

The assembly is relatively time-consuming to accomplish and consequently, expensive. Thus, the water pump casing, bearing and the system used for sealing the bearing to the water pump casing are relatively expensive parts which require considerable labor to produce. By apply a considerable amount of machining to finish the surfaces in order to obtain the accuracy necessary in the finished pump.

In addition, improving the bearing construction and wherein the bearing and bearing seal arrangement are considerably simplified to eliminate a considerable portion of the previously required machining and assembly operations. Thus, the improving of assembly can be lesser weight than the previously used.

Besides that, objectives of the invention is to substantially reduce the cost of manufacturing, assembling and handling the main component of the coolant pump used with an automotive-type engine, while simultaneously decreasing the weight but maintaining the dimensional accuracy of the water pump.

Chapter 3.4: Design for Manufacture rules (DFM)

The rule of DFM is protecting public safety and assisting the designer in performing high-quality work. Reducing the variety of parts that achieve the same function can have many benefits to the product development enterprise. Firm numbers on the cost of part proliferation are difficult to obtain, but estimates are that about half of manufacturing overhead costs are related to managing too many part numbers.

The benefits of the DFM rules are cost reduction, quality improvement, production flexibility, and manufacturing responsiveness. The specifics of benefits in each area are outlined here.

Cost reduction Purchasing costs Standardization of parts and the subsequent reduction in part numbers. This allow for flexible delivery schedules, quantity discounts, and less work for the purchasing department. Reduce costs through raw materials standardization Cost for in-house production of parts can be reduced if raw materials can be standardized to a single size of bar stock, tubing, and sheet metal. Metal casting and plastic molding operations can each be limited to a single material. Feature standardization Standardized the specification of radii in lathe turning or milling will reduced the maintenance a large inventory of cutting tools. Reduction of inventory and floor space requirements Reduction of inventory and floor space, tooling costs, and purchasing and other administrative costs will be decreased in overhead costs.

Quality improvement Product quality Reduces using wrong part in an assembly. Prequalification of parts The standard parts can be prequalified for use in new product without the requirement for extensive testing. Supplier reduction means improved quality Giving more business to fewer suppliers will be an incentive for developing stronger supplier relationships.

Production flexibility Materials logistics The flow of parts must within the plant. Reliable delivery of standard low-cost parts Restocked directly to points of use in the plant by parts suppliers using long-term purchase agreement.

Flexible manufacturing Eliminating setup operations allows products to be made in any batch size.

Manufacturing responsiveness Parts availability Fewer part types used in greater volume. Quicker supplier delivers By standardization of parts and materials. Financially stronger suppliers With larger volume orders and fewer part types to make.

As an engineer to design water pump not only to standardization from DFM rule but is needed to achieve a minimum-cost design is to create a minimum-weight design. The most economical approach is to select the next larger standard size of motor and pump to achieve adequate functionality.

In addition, Group Technology which is parts grouped into part families in terms of commonality of design features as well as manufacturing processes and processing steps is required. Thus, the benefits of Group Technology can be developed using previous similar designs with a great saving in cost and time. Another advantage of group technology addresses the trend among customers for greater variety in products.

4.1 IMPROVED PRODUCT DESIGN

Part/Component Casing 1 Gasket Pulley Hub Ball Bearing Shaft Cap seal with Spring Impeller Retaining Ring Bolt Bushing

Material Cast Iron Iron Grey Cast Iron Steel Carbon Steel Plastic Mild Steel, paint Carbon Spring Steel Cast Iron Bronze

Manufacturing Method Sand Cast By Supplier Sand Cast By Supplier Casting By Supplier By Supplier By Supplier Forging By Supplier

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4.2 How to Manufacture?

Each part of the water pump is manufactured using different method and it is formed by different materials. For Casing 1 the components are made by Sand Casting method and the material to manufacture it is cast iron. Sand Casting is a method used to build large components which is pouring molten metal into a cavity casted by sands. When the molten metal is cool it will formed as the same shape with the cavity and therefore the parts are build. This manufacturing method is using lower cost and even can be used in for refractory sufficiently therefore a lot of metal foundries are forming the parts using it. Other than casing the pulley hub in the water pump are formed using sand cast as well. Forging is another manufacturing method other than sand cast in for the components in water pump. It is one of the eldest well known manufacturing methods using in metal working process. Forging can be define explain as shaping of metal using localized compressive forces.

4.3 How to Assemble?

Water pump in a car engine consist of a lot components so normally the manufacturers are combining it into a part using hydraulic jet. It is needed to use this machine as we need a high pressure to push the entire component together to form the water pump. The attachment of all the parts is very important as it is needed to let a high pressure water to flow on the inlet to outlet. Therefore if it is not combined intelligently or the screw and the nut are loose, it will cause the engine to burst or even harm the drivers. Water pump will be needed to screw tightly on the bottom of the engine.

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4.4 DFM Rules

DFM (Design for manufacture) is one of the most used and abused buzzword today. This started when foundries where ramping up 0.13um production, many designs where hit with low yield problems. To improve yields, some design rules were modified. These design rules are sometimes referred to as DFM rules. At the same time, CAD tool vendors started to write software that would help improve yield, or check for potential problems. They also market these tools under DFM. There are also some design techniques that can help yield, such as memory redundancy and logic reconfiguration, which again may be thrown under the DFM world. Focusing on this rules can bring out safety issues and it is causing lower cost for the manufacture therefore it is encourage to apply the rule.

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4.1 Comparison Between Existing Design and New Design

Figure

The figure above is the improved design of the Casing for the water pump. We have redesigned the casing by changing the left side of the component into holes. The reason we are designing it to become hollow is to reduce the material used to manufacture this component. Reducing the material will make the cost of manufacturing this part lower comparing to the existing one.

Figure

Figure 2 is to show that the water inlet had been redesign from 2 holes into direct water inlet at the right side. We modify it because we found out that the existing design is using more effort to manufacture it and it is unnessacery to put another flat hole on the right side. We redesign it into a direct water inlet hole so that it is easier to be manufactured and so the manufacturing process can be easily done.

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Figure

For the bottom part of this casing we have change the complicated design in to a simple one .The purpose of redesigning it is to made it easier to design comparing to the existing one.

Figure

The top figure is the hub on the water pump. In the existing design it is separated into two parts and we are combining it into one piece. The new design of the shaft is as shown in the figure. The purpose of combine it is to make it easier to replace if it is spoil or rusted. Therefore the end user doesnt need to find the parts 1 by 1 and reduce parts will make the repairing job easier compare to the old design.

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Figure

On top is the new water impeller which has been redesign by us. It is more focus on the blade part as we found that the new impeller is more endure comparing to the existing one. The existing can be say that it i easier to get rust and exhaust. Other than that, the new design will be easier to be manufacture as it can be formed using sand cast or moulding method. The cost can be reduced and therefore the parts would not be too expensive when we need to replace it.

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