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Case Studies
DS Breaker Main Link
Weight: 0.88 lbs
Alloy: AB-200
Volume: 6,000/yr
Previous Method
- Part Steel Weldment (machining required after welding)
Points of Interest
- Previous strength requirements met with AB-200 material (tensile strength 95KSI min)
- Cost savings of approximately 35% over fabrication
- Eliminated zinc plating (corrosion resistance)
- Previous part had quality issues
Lower Stationary Contact
Weight: 20 lbs
Alloy: CU-110
Volume: 500/yr
Previous Method
- Machined Sand Casting
Points of Interest
- Sand casting could only maintain a 60% maximum electrical conductivity while permanent mold yields 97% minimum.
- Part ran 3 deg F cooler during heat rise test. (due to air cooling passages and conductivity)
- Part weight was reduced by 7 lbs.
- By eliminating or reducing machining operations and cycle time cost reductions of over 75% were achieved.
- Stocking program led to shorter lead times.
- Eliminated black painting due to higher conductivity/lower heat rise.
Upper VI Contact Block
Weight: 2.6 lbs
Alloy: CU-110
Volume: 1,500/yr
Previous Method
- Brazed, machined fabricated assembly
Points of Interest
- All though all parts of the former 4 piece assembly had high conductivity. Permanent mold provides a homogenous single piece product that performs better during heat rise tests and is electrically superior
- Cost savings of 80% were achieved.
- Note material savings, rounded edges, improved corona.
Manual Charging Lever
Weight: 0.8 lbs
Alloy: AB-200
Volume: 3,000/yr
Previous Method
- Stamping, brazed bushing, welded fabrication (6 separate parts)
Points of Interest
- 304SST pin cast in place.
- AB material has comparable strength.
- AB material has better corrosion resistance. (eliminates zinc plating)
- Casting as one piece has eliminated some machining.
- Major cost saving realized.
- Casting is far more aesthetically pleasing than the crude weldment.
MPCV Relay Can
Weight: 8.6 lbs
Alloy: B-100
Volume: 1,200/yr
Previous Method
- Copper deep draw w/ welded studs (4) & threaded inserts (6); also plated and painted
Points of Interest
- Corrected 41% rework & 20% scrap rate during assembly as a result of failed welded joints and deformation of deep draw during welding through the use of permanent mold.
- Eliminated plating and painting of parts due to alloy selection and casting finish.
- Brazed studs replaced by 304SST screws cast in place.
- Top & bolt pattern are machined in one step- eliminates alignment problems also allows pressure tight seal when assembled.
- Cost savings of 45% were achieved.
Lower Stud Assembly
Weight: 13 lbs
Alloy: CU-110
Volume: 250/yr
Previous Method
- 4 Part stamping riveted together
Points of Interest
- Single piece homogenous casting is electrically superior to riveted assembly.
- “Windows” are now a cast feature.
- The featured item is from network protectors. However, several higher volume parts from the DS breaker are similar conversions.
- Raised pad around cast diameter hole eliminated build up plating operation.
Cubicle Primary Contact Series
Weight: 13-18 lbs
Alloy: CU-110
Volume: 5,000/yr all styles combined
Previous Method
- 3 Part machined & brazed assembly
- Note: Photo is one version of a series of 12 similar parts
Points of Interest
- Eliminated machining operation by providing mounting holes as cast.
- Upper diameter was a sand casting. Permanent mold offers improved conductivity.
- Single piece homogenous casting is electrically superior to brazed assembly.
- Cost savings of 60% were achieved.
CMD Main Contact Block
Weight: 10 lbs
Alloy: CU-110
Volume: 300/yr
Previous Method
- Extruded copper
Points of Interest
- Permanent mold allowed the addition of cooling fins. This allowed substantial improvements in electrical and thermal efficiency.
- Permanent mold allowed for much smaller production runs versus the extrusion.
- Electrical conductivity is the same for both processes.
- Casting hardness of 40 HBN versus an extruded copper hardness of 50+ HBN was an issue that testing resolved.
Left Hand Stud Assembly
Weight: 17 lbs
Alloy: CU-110
Volume: 400/yr - each version
Previous Method
- Brazed & machined 2 part fabrication
- Noted: Part of a combination tool to produce center and right hand parts
Points of Interest
- Four studs cast in place eases assembly process.
- Critical as cast contact surfaces reduce cost with a minimal impact to the performance of casting.
- Over all performance far exceeds that of the two piece assembly.
- Cost savings of over 50% were realized.
- Weight reduction of 4 lbs.
Upper Brake Assembly
Weight: 2 lbs
Alloy: AB-200
Volume: 7,000/yr
Previous Method
- Designated for Permanent Mold
Points of Interest
- High strength requirements on both alloy and part design.
- Close machining tolerances (+/-0.0002”) on several bores.
- All machining done in house- turn key project.
- Corrosion resistance of alloy avoids plating or painting operations.
Shunt Output
Weight: 2.5 lbs
Alloy: CU-110
Volume: 5,000/yr
Previous Method
- Designated for Permanent Mold
Points of Interest
- Attempts as a fabrication failed. Permanent mold allowed the addition of fins for added cooling which allowed parts to pass testing.
- Contact areas required a 60 HBN min so we added a coining operation to harden cast copper. (which is about 40 HBN)
Charging Cam
Weight: 1 lbs
Alloy: AB-210
Volume: 8,000/yr
Previous Method
- Steel fine blanking w/ (4) additional parts welded on
Points of Interest
- Single piece casting versus 5 part assembly.
- Casting has eliminated some machining and zinc plating.
- Teeth are as cast.
- Cost of finished casting was less than the price of the fine blanking alone.
1200 Amp Contact Stab
Weight: 6.5 lbs
Alloy: CU-110
Volume: 10,000/yr
Previous Method
- Machined and bent bus bar
Points of Interest
- High failure rate (60%) from cracks and misalignment during the 180-degree bending operation.
- Base and upper sides are an as cast contact surface, lead-in radius is machined.
- Surface finish on contact “R” of casting is far superior.
- All holes are as cast.
- Piece price savings were 40%.
Arc Horn
Weight: 0.60 lbs
Alloy: CU-210
Volume: 12,000/yr
Previous Method
- 2 Part stamping riveted together
Points of Interest
- All machining is eliminated.
- Single piece casting out performed previous method during testing.
- CU-210 electrical conductivity of 77% min and hardness of 100 HBN competed favorably against an expensive non-standard material that was being used at the time.
Jam Nut
Weight: 17 lbs
Alloy: AB-230
Volume: 150/yr
Previous Method
- Machined complete from billet material
Points of Interest
- Castings tested at 25KSI and 400Deg-F.
- Entire inside configuration is now as cast. By the use of loose inserts- No sand cores.
- Mold has more than 20 sections & pieces.
- Weight reduction of 51 lbs/piece.
- Savings of over 350% were realized.
Magnum Main Link
Weight: 0.65 lbs
Alloy: AB-230-1
Volume: 9,000/yr
Previous Method
- Steel investment casting
Points of Interest
- Steel casting required heat treating and plating. These operations are eliminated by the use of AB material.
- Material savings were limited on this part. Real cost savings were realized by multi-cavity mold tool and high production machining fixture.
- Cost savings of 30% were achieved.