Description of Manufacturing Processes - Essay Example

Name: Course: Tutor: Date: Analysis and specification of manufacturing processes. Valves have been used for years for purposes of regulating or directing fluids in a given flow. They are widely used in many engineering fields and are usually classified as either open or closed valves. A foot valve can be described as a one way valve mainly used in regulating flow of fluids between regions of unequal pressure. A prime example where these valves are used is in wells where in conjunction with a jet pump prevents backward flow of water incase the pumping operation is stopped. The highlift foot valve is an integrated unit consisting of a check valve and a strainer and therefore its design should entail criteria to ensure that that the valve is not clogged up as a result of intake of big-sized particles. Key manufacturing methods for the 3’’ 300 MKIII highlift valve are governed by the design concept that will be greatly influenced by the operating principle of the valve as well as the unit components used to make the complete valve. With this regard, the highlift valve can be manufactured using two broad methods; computerized numerical control machining(CNC machining) and convectional machining methods. CNC machining entails the use of computers to control tools used in manufacturing of desired products. These tools are automated using programmed instructions that are fed to the machine via the controller hardware. These machines usually perform simultaneous functions on the work piece such as drilling, surfacing, welding , grinding amongst other manufacturing processes and as such product manufacture can be completed in much less time compared to convectional methods of machining. On the other hand, convectional machining methods involve the use of single machine operations to the work piece to achieve the desired final product. Normally these processes consume more time and labour with relatively less precision compared to modern CNC machining. There are both pros and cons to both machining processes which makes industry based firms to integrate the two processes for manufacture of their products. The highlift foot valve as earlier stated is consists of several components and as such poses challenges in one integrated machining process. Some of these parts include the plug and its seat and the main body on which the inlet and outlet ports are located. Below is a justification that makes convectional machining method as the most viable choice between the two processes. Key factors for consideration of convectional methods of machining include; 1. The body of the valve is designed to be of irregular shape to incorporate the piston shaped plug and to provide sufficient flow volume of the fluid in question without vast pressure changes. Such an irregular shape of the main body would sufficiently be manufactured using casting methods. 2. The different components used would most likely be manufactured from different sources before the final assembly. Some of these components such as the plug seat are delicate and would require a rather sophisticated CNC machine to achieve efficient assembly compared to convectional means. Sophistication of equipment and labour would be a case of inefficient manufacturing practicability. 3. The liftvalve should as simple as production facilities can allow. The general design as discussed above would be easily carried out using the cheaper convectional means compared to the sophisticated and more often CNC machining. 4. Moreover, thread making on the inlet and outlet ports of the valve can easily be made using lathes available in the company which further justifies the use of convectional machining. 5. The body of the lift valve is designed to be made of cast iron which makes casting of this part the best procedure to make this part. 6. CNC machining normally involves sophisticated software for production of a particular design. Changes to this design would not only be costly but also mind grueling. On the other hand, changes in design can easily be accommodated using convectional machining methods. The following procedure is used in the production of the highlift footvalve. 1. The main body made of iron is casted which involves melting the iron metal and pouring the semi liquid in a mould that is the female of the body of the footvalve and allowed to solidify. This solid part is then ejected out of the mold and allowed to cure. Testing for strength and brittleness may be carried out on stereotypes to ensure a compact and rigid body. 2. Lathe processing operations such as machining of the metal seat and dashpot components are then done. Thread-making on the inside surface of the inlet and outlet ports is also done at this stage using a lathe machine. The lathe is a key machine for machining and involves other procedures such as surfacing and minor boring. 3. Precision drilling may be done for nut holes and intricate holes not accounted for during the casting process. This is done using drills that are easily available in the facility. 4. Final assembly of the highlift foot valve component is then done to come up with the final product. This is duly followed by water pressure testing to ensure that the valve meets all registration requirements as governed by the company and global standards. 5. The final production procedures involve painting, packing and dispatch activities ready for shipping or delivery. Painting is done with regard to market demands or specific customer requirements. The paint used should however be non toxic and water insoluble since most of these valves are used in water based applications. Environmental standards should be adhered to in regard to the type of paints used. Below is a breakdown of the cost analysis used for the production procedure used; SN Item Units Unit cost ($) Total cost ($) 1 Cast iron 850 gms 15 2 End fittings - - 4 shims 4 pieces 0.75 3 3 Internal O rings 5 pieces 3 9 Paint 20 1 4 Operational cost(inclusive of machining costs) - - 11 5 Transport 3 - 6 6 Labour - 9 7 Miscellaneous accessories - - 7 Total cost 65 CONCLUSION The 3’’ 300 MKIII highlift footvalve is sufficiently designed and manufactured by convectional machining methods at the expense of the more sophisticated CNC machining procedures. This has allowed full use of resources at the facility while at the same time keeping the cost of the entire unit at a an affordable price. 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