Mechanical Design Department Design Standards & Practices

Materials & Finishes

Materials & Finishes..........................................................................................................1 Material Selection.........................................................................................................2 Bosch Extrusion............................................................................................................3 Processing of Bosch Extrusion...................................................................................3 Carbide and custom punches.......................................................................................4 inishes...........................................................................................................................! Finishing and tank sizes .............................................................................................6 Electropolished Sur"aces..............................................................................................#

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Mechanical Design Department Design Standards & Practices

Material Selection
1. 'se stock (ateria) sizes *hen e"er $ossi+)e to e)i(inate unnecessar, (achining -See $%3 &a' Materials & Stoc( asteners ) on the Mechanical *ebpage+. Purchasing !a* /ateria)s0 2. 1hen re2uiring too) stee)% 341 distorts *hen heat treating and thus $ro+)e(s *ith not enough (ateria) )eft for grinding% on), use 341 *hen ,ou need so(ething +etter than (i)d stee) +ut do not re2uire heat treating. ," heat treatment o" tool steel is necessar- than use .2. 5f in 2uestion consu)t ,our su$er"isor. 3. !adia) +earing shafting shou)d +e (ade fro( 6ho($son75na7Barden or #u$erior #hafting de$ending on the a$$)ication. 8ertain a$$)ications *i)) re2uire the use of #tress Proof #tee) or 31 -*i)) re2uire a )ot of *ork for finishing. 4. 1here"er $ossi+)e use 9)u(inu(% it *i)) sa"e ti(e and (one,. 96# uses it in se"era) for(s% 6&61466 9)u(inu(% 6&61466 9cracut 9)u(inu( -accurate), cut to *idth.% 8ast 9)u(inu( 6oo)ing P)ate -)ess susce$ti+)e to *ar$age% f)at and tight to)erance in thickness.% and 9)u(inu( ang)e. 1hen +ending a)u(inu( use 3&&34:14 not 6&61466. 9)) of the a+o"e (ateria)s ha"e uni2ue to)erances -see ;<a,o)d2 on :2(ain -=>. under re$orts ? shortcut to $urchasing ra* (ateria)s@.. 5. 6he hardness for too) stee)s *i)) +e )i(ited to three +asic grou$s do not s$ecif, an,thing outside these grou$s un)ess a+so)ute), necessar,A 1. !8 44446 2. !8 54456 3. !8 6&462 4'sed *hen $art shou)d +e tough +ut not necessari), hard. -i.e. shafts% $ins% etc.. 4Benera) $ur$ose *ear ite(s. -i.e. gi+s% s)ides% co"er $)ates% "4s)ides for he$co ro))ers% etc.. 4:ea", *ear surfaces. -i.e. cutters% $unches% for(ing too)s% etc..

6. 6he to)erances of (ateria) stock (ust +e considered in a)) too) designs. -see ;!e$orts on ne*Co+ :2fi)e -B>. under <a,o)d@ ? shortcut to $urchasing ra* (ateria)s@. . Be carefu) *ith ,our use of 8!#. 5t is "er, susce$ti+)e to *ar$age +ecause of itsD interna) stresses. 5t shou)d +e used *here (ini(a) (achining is +eing $erfor(ed. 8. 6he )ist of (ateria) t,$es 96# has standardized on is )i(ited to those )isted in the +a))ooning (acro. =i(it ,our use of (ateria)s to these un)ess other*ise s$ecified. 21546698 .doc !e" date #e$t 11% 2&&6 2

Mechanical Design Department Design Standards & Practices

9. :ot !o))ed #tee) *i)) +e ordered either +)anchard ground or sand +)asted. <o not order it in *ith a sca)e finish% as this *i)) (ake it "er, difficu)t to finish. 1&. 5f ,ou are hardening too) stee) it (ust +e di(ensioned in the detai) dra*ing such that there is grinding a))o*ance -ie. &.365 for 378 (ateria).

Bosch Extrusion
#tock at 96# #tandard> 3& E 3& B3#8: EE6!'#53F 45 E 45 B3#8: EE6!'#53F 45 E 9&-=. B3#8: EE6!'#53F 9& E 9& B3#8: EE6!'#53F 45x45 8)ean !oo(> 1F #5FB=E #=36 -45E45 B3#8: EE6. 2F #=36 3PP -45E45 B3#8: EE6. 2FG# #=36# 9<H -45E45 B3#8: EE6. 3F 6!54#=36 -45E45 B3#8: EE6.

Processing of Bosch Extrusion

Guarding (reference Guarding Guidelines) Stock extrusion single manufactured item, qty = 1 Non-stock extrusion Single purchased item; quantify how many 6m lengths required to completed guarding assem ly Non-guarding application Stock extrusion Non-stock extrusion indi!idual manufactured item purchase each piece including length to e cut " purchasing will ta ulate total amount of extrusion to purchase #$ of 6m lengths% create manufactured item for any piece requiring angular cut

Non-guarding extrusion part groupings can e de!eloped as a manufactured assem ly #which will put it in the &&&1-&''' num er range% if it is a S( assem ly file, or )ust simply as a manufactured part if it is drawn using the structural mem ers function in S(* +his will allow designers to create a detail drawing containing a ,-. to show in more detail exactly how the extrusion is to e assem led*

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Mechanical Design Department Design Standards & Practices

Carbide and custom punches

1. 9)) car+ide co($onents *i)) +e done outside. 5n /E8: *hen creating the record $)ease $ut 8ar+ide under the (anufacturer and then for descri$tion ca))out $art na(e $er 96# <ra*ing. /nder material on the detail place material and purchase number0 example C2 1,2EM 34%%5. #$ecif, 82 un)ess ,ou need a s$ecific t,$e of car+ide. /anufacturer> Part I> <escri$tion> 8ar+ide EEEE4EEE4&&1 -!e" if needed. Fest $er 96# <ra*ing

2. 9)so $unches -nor(a)), 92 or /2. *i)) +e done outside. 5n /E8: *hen creating the record $)ease $ut 8usto( Punch under the (anufacturer. /nder material on the detail place material and purchase number0 example .2 1,2EM 34%%5. /anufacturer> Part I> <escri$tion> 8usto( Punch EEEE4EEE4&&1 -!e" if needed. 92 $er 96# <ra*ing

Material Compatibilities for Vapori ed !"drogen #eroxide

1. 8o($ati+i)it, is defined as the (ateria)s a+i)it, to undergo ex$osure to "a$orized h,drogen $eroxide *ith no significant changes in $h,sica)% or che(ica) $ro$erties -i.e no changes in strength% f)exi+i)it,% che(ica) co($osition% co)or etc... 8)ick on )ink to "ie* )ist of (ateria)s and their co($ati+i)ities. Gh$co($a.doc.

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Mechanical Design Department Design Standards & Practices

$inishes
1. 9)) (ateria)s% if a$$)ica+)e% *i)) s$ecif, a finish. 6he finish is s$ecified during the +a))ooning $rocedure and is noted on the detai) dra*ing. 3$tions for the (ateria) finish is $ro"ided during the +a))ooning $rocedure. 2. 6he fo))o*ing chart s$ecifies the standard 96# finishes. 6he standard finishes are a)so detai)ed in the ;96# <esign #$ecification #u((ar,@. 6ote7 'hen speci"-ing paint0 al'a-s callout paint per .DSS. M.2E&,.8 6a+)e Base Buarding <ucting% E)ectrica) $ane) 9ir :eaders 1e)d(ents -a+o"e ta+)e. 9)u(inu( /i)d #tee) 6oo) #tee) 6a+)e 6o$% :!# ,6,S9 1pre"erred choice5 Paint4 <ark Bre, Paint4 =ight Bre, Paint4 =ight Bre, Paint4 =ight Bre, Paint4 F)at B)ack -8)ear 9nodize.% B)ack 9nodize% :ard 9nodize -B)ack 3xide.% :ard 8hro(e% E)ectro)ess Ficke) -:ard 8hro(e.% B)ack oxide% E)ectro)ess Ficke) Ficke) F)ash

3. 5n (ost cases the finish *i)) add to the (ateria) thickness. Jno* the finish and if necessar, consu)t so(eone on the effects of the finish. :ard chro(e> .&&&2 4.&&&5 inch 9nodize> .&&&2 4.&&&4 inch B)ack 3xide> .&&&1 4 .&&&2 inch Ficke) f)ash> .&&&5 4 .&&1& inch E)ectro)ess Ficke)> .&&&4 4 .&&&5 inch -$er 9#6/ B 33% 6,$e 4% #82% 8)ass 1. :ard 9nodize> .&&&5 4.&&&8 inch 4. 5n the design of gauges or setu$ too)s *here there is high to)erance $ieces finish the $ieces *ith B)ack 3xide. 5. 6he finishes s$ecified do not re2uire a $rocess s$ecification. 6he sho$ has detai)ed $rocedures for the finishing $rocesses. 6. 8ertain custo(ers *i)) re2uire their co)or finishes for $ainted co($onents. 6his *i)) +e detai)ed in the ;9<##@.

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Mechanical Design Department Design Standards & Practices

. 8ertain a$$)ications re2uire case hardening rather that heat treat. 6hese are re2uired for ite(s that re2uire surface hardening% +ut (a, not *ar$ i.e. in)ines. Exa($)es of case hardening are> 9rcor4P: 4 si(i)ar to tenifer% +ut can go dee$er *ith the hardening -u$ to .&&2 dee$. 6enifer 7 6rinide4 -u$ to .&&&2 dee$. 6itaniu( Fitride -65F. 4 -u$ to .&&&2 dee$. 8. 1e)d(ent dra*ings need to indicate surfaces that are not to +e $ainted.

Finishing and tank sizes

Process 8)ear 9nodize B)ack 9nodize :ard 9nodize B)ack 3xide (Ampere Metal Finishing) (ATS Systems) :ard 8hro(e Ficke) F)ash E)ectro)ess Ficke) Metalon Technologies (steel) Metalon Technologies (aluminum) General Magnaplate (Industrial Processing) *or(ing .rea o" 2an( 1inches5 2& x 5& x 92 2& x 5& x 92 2& x 5& x 92 24 x 4& x 18& 23 x 23 x 24 48 x 48 x 12& 24 x 82 x 92 36 x 48 x 49 16 x 24 x 32 48 x 6& x 96 12 x 36 x 54 *eight &estrictions 1lbs5 2%&&& 2%&&& 2%&&& 2&&& 1%5&& 1%5&& 6%&&& 4%&&& 4&&

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Mechanical Design Department Design Standards & Practices

Electropolished Surfaces
-5nsert fro( 9#6/4938&. E)ectro$o)ished surfaces are extre(e), s(ooth% (acrosco$ica)), f)at% (icrosco$ica)), feature)ess% and exhi+it high high )uster% ref)ecti"it, and +rightness. E)ectro$o)ishing su+stantia)), reduces the surface area a"ai)a+)e for conta(ination $ick4u$ and e)i(inates a)) (icro4cracks and interna) cre"ices. 8o($arison 6a+)e <ifferences Bet*een Po)ished and Buffed /i))ed Finishes% 9+rasi"e Brit Fu(+ers and #urface !oughness -Before and 9fter E)ectro$o)ishing. Before E)ectro$o)ishing #urface !oughness !a /icro(eter 3.56 (ax 1.14 (ax &.64 (ax &.2&4&.51 &.154&.38 &.1&4&.25 9fter E)ectro$o)ishing #urface !oughness !a /icro(eter /icroinches 1. 842.25 &.5 4&. 5 &.324&.4& &.1&4&.26 &.&84&.19 &.&54&.13 &49& 2343& 13416 441& 348 245

/i)) Fo. 3 4 8 8

Brit Fo. 6& 12& 18& 24& 32& 5&&

/icroinches 14& (ax 45 (ax 25 (ax 842& 6415 441&

KGa)ues are a$$roxi(ate. E)ectro$o)ishing genera)), reduces surface roughness readings of a non4E)ecro$o)ished surface +, 5& $ercent. #(oothness is not an inde$endent "aria+)e in surface definition. 5t is one factor of an i($ortant su+Cect that is referred to as ;surface (eta))urg,.@ #(oothness s$ecifications% +ased on gages% can +e achie"ed +, +oth E)ecto$o)ishing and +echanica) a+raci"e finishing techni2ues.

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