149 a:4:{s:8:"template";a:1:{s:27:"Work Instruction-print.html";b:1;}s:9:"timestamp";i:1367210378;s:7:"expires";i:1367213978;s:13:"cache_serials";a:0:{}}010020925 Routing


Created Modified Rev. Changed by Change
05/08/06 12/19/08 28 Mathias Add metal band check in step 10



 1. BAG

Material: 20118

Start with weight of 2.37# and adjust to get a Raw sleeve length of 5.519+/-(1/16") .This material is molded per next step.

 Scale, Scoop
 2. MOLD    Clean mold, pin & pads. Load the powder weight, press at 12.7 tons, Dwell: 1st side(45 sec) , turn and press 2nd side(60 sec) with a feed of 10 , Trim excess material Min.tonnage will be 9.4 for min spec. gravity.

 MOLD: 3.125 X 1.875 On Mold Rack

PRESS: B-23

 3. OVEN Sinter using WALL-2 recipe. Measure sleeves when unloading - sleeves should be 5.850 min. length. Bring sintered sleeves to machining area.   Computer program and Instructions

 4. CNC

Op.#1

Manufacturing Drawing #: 010020925 rev.F

Inspection Drawing #: 010020925 Borg Warner rev E

Machine part with pre-formed lip forward. Use tooling specified in program.

Place machined parts in Traveler Buckets with pre-formed lip facing up.

Machine: Okuma 2-turret CNC lathe

Program: BW-010020925.MIN

Target: 12 pcs/slv

5. CNC   

Op.#2

Tooling: #36 Tool Block stored in ML3 cabinet. Locate tool block in hole #6 on ML3. Use ThinBit #  CN028031A (Bin D-13) Collet #D-42. Screw collet in snugly, back out 1 full turn.

Machine band groove per drawing. Verify .045 Â± .003 dimension with custom .025 Blade Micrometers.

Place finished parts in Traveler Bucket with pre-formed lip facing up.

Haas Mini Lathe #3

Program: #O00555

(010020925-2OP)

6. BAND

Material: .012 x .175 301ss band stock

Outer Band Diameter: 2.885 Â± .004

Inner Band Diameter 2.860 (nested with outer band)

When nesting the bands, welds must be 180 degrees apart. Bands must be nested prior to installation into the seal.

Run bands in 100pc. batches. Inspect first and last band from each batch for O.D. diameter and weld quality.

Automatic band machine

qty. 1 per seal

7. FORMING
  1. Verify mandrel diameter before starting production run
  2. Place seal into slot with machine formed lip facing operator
  3. Cycle forming mandrel
  4. Rotate fixture to eject seal
  5. Stack finished parts with machined lip facing up
2.050 diameter pneumatic forming tool
8. ASSEMBLY Install metal band into band groove in seal. Band must be recessed to back of groove.  
9. INSPECT Verify dimensions per Inspection/BW print 010020925 rev E.

 

10. PACKAGING & SHIPPING
  • Stacked 30pcs high, with dust lip facing up
  • Inspect 100% of parts for presence of metal band 
  • Inspect the dust lip of the end sleeve for damage before wrapping in plastic
    • If repackaging is required avoid using a utility knife to open the packages and recheck the dust lip for damage
  • Cover with a 2-mil clear plastic sleeve, the ends of the sleeve are tucked into the center of the end parts  
    • Extra material around the diameter of the sleeve is taped in place with clear packing tape  
  • Sleeves are placed vertically into the bucket, 8 sleeves total. The dust lip must still face up 
  • Place packing material (foam peanuts, news paper, bubble wrap, etc) down the open areas between the sleeves to restrict the movement of sleeves in shipping
  • A layer of cardboard will cover the top of the parts with a layer of bubble wrap over the cardboard.
  • Close the Bucket using new lid
  • Affix Barcode Label
  • Address and ship.

    9"x10"x13" Plastic bucket

    2-mil clear plastic sleeve

    Bubble Wrap

    Packing Tape