Document Type

Dissertation/Thesis

Date of Degree Completion

Spring 2016

Department

Mechanical Engineering Technology

Committee Chair

Dr. Craig Johnson

Second Committee Member

Neal Hauff

Third Committee Member

Casey McFarlen

Abstract

The concept of conversion casting makes manufacturing major components much more efficient with regards to time and cost. The conversion cast of the adapter hub used in the Victair Mistifier is a major component that requires 8 hours to machine. The existing hub starts from steel stock and then that block of steel is placed into a CNC machine and coded in to create the adapter hub. The manufacturing method changes to a casting for the adapter hub will create a replicated part that requires 1.5 hours of post machining. The intricate design makes a conversion to casting more effective in reducing time and costs, because the cast part will be near-net shape.

The original design was redesigned to be castable with the addition of casting components onto a pattern bed to create a match plate. In order to make this project economical and the final product as close to the net design of the adapter hub, shrinkage of the material was placed into consideration and casting formulas were used to create the smallest gating system as possible. Draft angles were added to all faces of the adapter hub design and filleted edges around the overall design were added for easy removal from the casting flask. This process reduces time and costs by $157 while also providing H.F. Hauff, manufacturer of the Victair Mistifier, the ability the mass produce a critical component of their most sold product. This in turn should lead to reduced costs for their customers.

Comments

Many of the drawings needed to be removed from this report due to company disclosure contract that was signed prior to this project. I apologize for the inconvenience.

Project web site: http://jmcsapp99.wix.com/mechanicalengineer

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