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Improvement deburring consistency of fuel nozzle parts

Seyedehshaghayegh Rouzmeh

Masters thesis (2012)

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Cite this document: Rouzmeh, S. (2012). Improvement deburring consistency of fuel nozzle parts (Masters thesis, École Polytechnique de Montréal). Retrieved from https://publications.polymtl.ca/940/
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Abstract

RÉSUMÉ: L'objectif de cette étude est d'améliorer la qualité produite par l'ébavurage des pièces de tourbillon d’air. Ces pièces de haute précision sont habituellement ébavurées de façon manuelle par un humain. Comme première étape vers l'amélioration de ces ébavurages, l'analyse des causes fondamentales a été réalisée. Puis les conditions actuelles des pièces ont été étudiées par des expériences utilisant la méthode de Taguchi. L’analyse de la variance a été menée sur les données recueillies pour illustrer la significativité des facteurs des plans d’expériences et de leur contribution. La formation de bavures sur les pièces a été étudiée, trois régions principales ont été analysées. Le modèle cyclique de formation de bavures a été observé à l'état d'équilibre de la formation de bavures. L'amélioration du profil de bavure a été réalisée suivant deux méthodes : 1) le liquide de refroidissement à travers les trous d’huile du foret et 2) en position verticale du perçage. Le procédé d’ébavurage avec des abrasifs magnétiques a été évalué comme une alternative possible pour l'ébavurage manuel. Les échantillons ont été traités sous deux conditions : 1) pas de préparation en sortie de trou après perçage et 2) sortie de trou préparée. Les échantillons dont leurs arrêtes (sorties de trou) ont été préparées, ont montré une amélioration significative en terme de régularité.----------ABSTRACT: This study is about improving the deburring consistency of air-swirlers. The parts are high precision critical components of hot section of aircraft engine, which have key role in stabilizing the combustion flames via providing turbulent air-fuel mixture for the combustion chamber. The product needs to meet high standards including edge quality and surface finish. These small in process parts are deburred manually due to their size, complex geometry, restricted access and adjacent critical surfaces to the edges. The title of the research was selected through investigations, cost estimation and prioritization of deburring issues within Pratt and Whitney Canada. In order to tackle the issue, a comprehensive study was conducted on state of the parts. The investigation aimed to lay a basis of comparison to evaluate the further improvement approaches. The parts were investigated through experiments, designed based on Taguchi method. For designing the experiments, root cause and fault tree analysis was performed first. Then the preliminary experiments were employed to define the level of affecting parameters. The designed experiments were conducted on four different in process parts. The data was analyzed using STATISTICA software. Based on the results, the areas, which required further investigation, were identified and feasible improvement strategies were proposed. The complementary experiments comprise two main topics: burr control and alternative deburring process. In order to improve the burr characteristics of the parts, burr formation study was conducted. The parts were assessed during various manufacturing cycles. Burr formation pattern was identified on the parts. Based on observation it was concluded that the pattern could be attributed to the temporary degradation of tool properties due to elevated temperature cutting during short time intervals. Hence, the temperature of the cutting tool was measured during production via thermal sensors. With respect to validation of hypothesis two main strategies were proposed in order to provide proper and homogenous cooling to reduce the tool temperature during the cut: Coolant thru design drill and vertical position for production. Both approaches revealed significant results. The burr height decreased and burr profile improved using both methods.

Open Access document in PolyPublie
Department: Département de génie mécanique
Dissertation/thesis director: Marek Balazinski and Canam Hoang
Date Deposited: 14 Nov 2012 14:53
Last Modified: 27 Jun 2019 16:49
PolyPublie URL: https://publications.polymtl.ca/940/

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