HARTWELL CORPORATIONUC IRVINE

MAE 188Engineering Design Industry

Flush Handle Latch Assembly Redesign

Students Faculty Advisors Hartwell Corp. Engineers

Jeremy KimKevin WenPhong DiepYuk Ming Wong

Derek Dunn-RankinHaris J. CatrakisJ. Michael McCarthy

Frank T. JacksonJohn F. GillenTim Rozema

Goal Statement

• Redesign the H3414-33 flush handle latch assembly to reduce its manufacturing cost and improve its wearability.

Flush Handle Latch Assembly H3414-33

•H3414-33 has 92 parts per assembly •Customers

– Canadair – Bombardier

Specifications

Metric Marginal Ideal

Cost $ each forquantity of 100

Less than current(< $1302.46)

20% less($1041.97)

Plating usage # parts 50% less None

Durability Cycle/return 30,000 300,000

Functionality Qualitative Same Same

Externalgeometry

Qualitative Same Same

Weight Lbs 20% less(5.4)

50% less(3.3)

Temperaturerange

°F -50 to 200 -80 to 300

• Cost Analysis – Cost analysis is based on Cost Auditor

Quote with quantity of 100

– Total manufacturing cost = $1,302.46

– Labor cost includes overhead rate factor of 4.03 (burdened labor)

– 4 categories of manufacturing cost• Burdened Labor

• Material

• Outside Processing

• Purchase Each

Total Manufacturing Cost Breakdown 02/05/01

B Labor52.13%

MATL34.07%

O/P6.80%

PurEa6.99%

ASSEMBLY NUMBER : H3414-33 QTY: 100 RCVD DATE :Rev :

DESCRIPTION: NOTES: Total Manufacturing Cost(TMC)

Hours ** Direct Cost **

Itm PART NO. DESCRIPTION QTY TYPE S/U Ea. Pc RATE LABOR B Labor %TMC MATL %TMC O/P PurEa Mfg Cost

4 132797-600 handle unpainted 1.00 MF 14.25 1.724 15.16 $28.30 $114.03 11.04% $75.34 7.30% $42.50 $0.00 $231.8730 117063-9 housing 1.00 M 10.50 1.166 14.76 $18.76 $75.60 7.32% $85.75 8.31% $7.00 $0.00 $168.3535 119922-3 actuator 1.00 M 8.50 0.613 14.87 $10.38 $41.83 4.05% $53.75 5.21% $3.00 $0.00 $98.5839 117067-5 collar 1.00 M 5.00 0.406 15.43 $7.04 $28.36 2.75% $41.30 4.00% $1.50 $0.00 $71.16

101 H3414-33 latch assy flush handle 1.00 A 0.00 1.373 12.69 $17.42 $70.22 6.80% $0.00 $0.00 $70.2241 117068-3 release lever 1.00 M 2.75 0.274 16.45 $4.96 $19.99 1.94% $35.42 3.43% $1.50 $0.00 $56.9146 118616-1 cover 1.00 M 5.50 0.265 14.77 $4.73 $19.05 1.84% $25.65 2.48% $1.00 $0.00 $45.7053 MS21151-8 ABR4M-8 1.00 P1 $0.00 $32.50 $32.5032 117065-3 inner support 1.00 M 6.50 0.420 14.81 $7.18 $28.95 2.80% $2.00 0.19% $1.50 $0.00 $32.442 103966-9 trigger 1.00 MF 3.25 0.202 16.26 $3.81 $15.37 1.49% $17.00 1.65% $0.00 $0.00 $32.37

21 130506-5 actuator rod 1.00 M 4.00 0.424 15.05 $6.98 $28.14 2.73% $1.83 0.18% $0.00 $0.00 $29.9728 132908-3 fitting 1.00 M 3.25 0.275 15.96 $4.91 $19.78 1.92% $2.55 0.25% $6.00 $0.00 $28.3374 130383-1 plate 1.00 M 2.75 0.132 14.53 $2.32 $9.34 0.90% $9.20 0.89% $0.00 $0.00 $18.5464 HSP226CDC1650AA spacer 1.00 M 3.00 0.196 14.24 $3.22 $12.97 1.26% $0.02 0.00% $0.00 $0.00 $12.9912 119667-1 spring leaf 1.00 P2 $0.00 $7.40 $7.401 H3414-35 handle assy 1.00 MF 0.00 0.133 12.70 $1.69 $6.81 0.66% $0.00 $0.00 $6.81

90 132390-1 spring 1.00 P2 $0.00 $6.30 $6.3034 117066-3 actuator assy 1.00 MA 0.00 0.125 11.54 $1.44 $5.81 0.56% $0.00 $0.00 $5.818 119668-3 trigger lift assy 1.00 MA 0.00 0.010 9.41 $0.09 $0.38 0.04% $5.00 $0.00 $5.38

96 118654-1 actuator screw 1.00 M 2.00 0.060 15.25 $1.22 $4.92 0.48% $0.24 0.02% $0.00 $0.00 $5.1691 HSP221HWW730AA bushing 1.00 M 2.25 0.069 13.52 $1.24 $4.99 0.48% $0.12 0.01% $0.00 $0.00 $5.1173 130331-5 link assy 1.00 MA 0.65 0.095 12.24 $1.24 $5.01 0.48% $0.00 $0.00 $5.0125 132077-1 guide button 1.00 P2 2.50 0.043 15.23 $1.04 $4.17 0.40% $0.10 0.01% $0.00 $0.00 $4.2748 119117-1 target spring 1.00 P2 0.00 0.001 16.20 $0.02 $0.07 0.01% $1.00 $3.20 $4.2776 130384-5 link 1.00 M 1.55 0.057 14.05 $1.02 $4.11 0.40% $0.13 0.01% $0.00 $0.00 $4.2349 NAS1423C6 nut 1.00 P1 $0.00 $3.70 $3.7024 107846-1 spring-dt trigger 1.00 P2 $0.00 $3.40 $3.4038 22DU12 bearing 2.00 P1 $0.00 $2.80 $2.8081 HSP148-9-093-680 rivet 2.00 M 1.50 0.031 14.30 $0.66 $2.65 0.26% $0.13 0.01% $0.00 $0.00 $2.7883 HSP221JDC525AA bushing 2.00 M 1.75 0.038 14.04 $0.63 $2.55 0.25% $0.13 0.01% $0.00 $0.00 $2.6819 HSP226CDC530AA spacer 1.00 M 1.00 0.039 14.19 $0.61 $2.46 0.24% $0.01 0.00% $0.00 $0.00 $2.4758 Q4126-559N quad ring 2.00 P1 $0.00 $2.00 $2.0023 117069-5 spring 1.00 P2 $0.00 $1.90 $1.9085 HSP108-4-093-320 rivet 4.00 M 1.00 0.027 14.31 $0.41 $1.67 0.16% $0.14 0.01% $0.00 $0.00 $1.8215 HSP115P094-1250 pin 1.00 M 1.25 0.020 12.93 $0.42 $1.69 0.16% $0.10 0.01% $0.00 $0.00 $1.7979 HSP115B094-1000 pin 1.00 M 0.75 0.026 12.96 $0.43 $1.75 0.17% $0.03 0.00% $0.00 $0.00 $1.7859 Q4125-559N quad ring ethylene 1.00 P1 $0.00 $1.70 $1.7044 117075-3 name plate 1.00 M 1.63 0.013 12.59 $0.37 $1.49 0.14% $0.02 0.00% $0.00 $0.00 $1.5143 117069-1 spring 1.00 P2 $0.00 $1.40 $1.4062 Q4025-559N quad ring 1.00 P1 $0.00 $1.20 $1.2098 HSP115B062-350 pin 1.00 P1 0.50 0.015 13.41 $0.23 $0.92 0.09% $0.01 0.00% $0.25 $0.00 $1.1868 5710-134-30P cres washer 1.00 P1 $0.00 $1.00 $1.0066 HSP115P094-1865 pin 1.00 M 0.58 0.011 11.18 $0.19 $0.76 0.07% $0.14 0.01% $0.00 $0.00 $0.9017 HSP115B094-900 pin 1.00 M 0.58 0.009 10.51 $0.16 $0.63 0.06% $0.03 0.00% $0.00 $0.00 $0.66

Modified Cost Auditor Quote by TMC

Totals for Top Assembly 134 89.90 8.326 $133.55 $538.21 52.13% $351.80 34.07% $70.25 $72.20 $1,032.46

TOTALS

TOTAL LABOR $133.55 OVERHEAD RATE 4.03 (x)

BURDENED LABOR $538.21 OUTSIDE PROCESSING $70.25 MATERIALS $351.80 PURCHASING $72.20 (+)

TOTAL MANUFACTURING $1,032.46 G & A RATE 1.32 (x)

TOTAL COST $1,362.84 PROFIT RATE 1.15 (x)

UNIT SALE PRICE $1,567.27

Cost

CostH3414-33 Manufacturing Cost

$231

.87

$98.

58

$71.

16

$70.

22

$56.

91

$45.

70

$32.

50

$32.

44

$32.

37

$29.

97

$28.

33

$18.

54

$400

.23

$498

.80

$569

.96

$640

.18

$697

.08

$742

.78

$775

.28

$807

.73

$840

.09

$870

.06

$898

.39

$916

.93

$168

.35

$231

.87

$0.00

$100.00

$200.00

$300.00

$400.00

$500.00

$600.00

$700.00

$800.00

$900.00

$1,000.00

Quantity: 100 Labor includes Overhead Rate (Burdened Labor) 02/09/01

Mfg Cost

S Mfg Cost

H3414-33 Manufacturing Cost As % Of TMC

22.5

%

16.3

%

9.5%

6.9%

6.8%

5.5%

4.4%

3.1%

3.1%

3.1%

2.9%

2.7%

1.8%

38.8

% 48.3

% 55.2

% 62.0

%

67.5

%

71.9

%

75.1

%

78.2

%

81.4

%

84.3

%

87.0

%

88.8

%

22.5

%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Quantity: 100 Labor includes Overhead Rate (Burdened Labor) 02/09/01

%TMC

S %TMC

• Approach– 92 total parts

– 13 most expensive parts make up 88.8% of the total manufacturing cost

– 4 most expensive parts make up over 55% of the total manufacturing cost

– Identify the 4 most expensive parts • 132797-600 Handle : $231.87 (22.5% TMC)

• 117063-9 Housing : $168.35 (16.3% TMC)

• 119922-3 Actuator : $ 98.58 ( 9.5% TMC)

• 117067-5 Collar : $ 71.16 ( 6.9% TMC)

– Individual cost analysis for these 4 parts• material

• burdened labor

• outside processing (O/P)

• purchase cost of each (PurEa)

– Redesign/replace the costly components with less expensive alternatives

– Other candidates• H3414-33 : $70.22 (6.8% TMC)

• 117068-3 : $56.91 (5.5% TMC)

Cost Breakdown Of 4 Most Expensive Parts

$114.03

$41.83

$75.60

$28.36

$41.30

$53.75

$85.75

$75.34

$1.50

$3.00

$7.00

$42.50

$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

handle132797-600

housing117063-9

actuator119922-3

collar117067-5

Part

Cos

t ($

)

O/PMATLB Labor

Cost

Wearability

Coating and paint chipping (132797-600)

Wear on inner of collar (117067-5) Wear on inner support (117065-1)

Wear on handle shaft (132797-600)

WearabilityWear sensitive parts

Part Trouble Probable Cause Corrective Action

(110B)(115B)(140A)

Outside handle does not extend to operating position when trigger (115B) is pushed.

Damaged or improper installation of spring trigger (140A).

Check spring for deformation. Replace the damaged parts.

(90)(110B)(315B)

Excessive torque required to turn the outside handle assembly.

Binding between the actuator fitting (90) and/or the housing (315B).

Clean and check components for uneven or excessive wear and worm through areas in solid film lubricant. Repair or replace parts.

(90)(220)

Actuator does not turn the required angle.

Damaged or improperly installed actuator fitting (90) or actuator (220)

Check the components for damage. Repair or replace parts.

(110B)(65A)

Excessive force required to push the outside handle assembly (110B).

Binding between the inner support (65A) and the rod (165B).

Check the inner support and the rod for damage. Replace the damaged parts.

(80)(160)

Outside handle does not extend to operating position when trigger is pushed.

Damaged springs (80 or 160). Check spring for deformation. Replace the damaged spring.

(65A)(165B)

 

Outside handle does not extend to operating position when trigger is pushed.

Binding between the inner support (65A) and the rod (165B).

Check the inner support and the rod for damage. Replace the damaged parts.

(290) Outside handle does not extend to operating position when trigger is pushed.

Bent pin (290) Replace the pin.

Hartwell Corporation, Components Maintenance Manual Part Number H3414. Fault isolation.

Technical Issues

• Materials

• Manufacturing Process

• Machining

• Functional Design

Materials

• Coatings– Housing Cavity (Except Area of Prox Switches) and Inner Surfaces of Handle are coated with Emralon 310

PTFE

• Electroless Nickel Plating – Handle Assembly

• Painting– Customer Choice

Density Tensile S trength Elongation Modulus of Elasticity CTE, Linear Thermal Conductivity

Current Materials

17-4ph Stainless Steel (Handle) 7.65 g/cc 160 ksi 11% 29,000 ksi 6.1 m(ºF)-1 9.5 Btu/ft-h-°F

A356.0T61 Aluminum Alloy (Housing, Actuator and Collar) 2.7 g/cc 41 ksi 10% 10000 ksi 11.9 m(ºF)-1 87 Btu/ft-h-°F

Alternative Materials

RTP Company Grade 3887 Polyary letherketone (PAEK) Carbon Fiber 40% 1.45 g/cc 38 ksi 0.8% 5,207 ksi 7.9 m(ºF)-1 6.5 Btu/ft-h-°F

DSM KetronTM PEEK 30% CF (Inj), Polyetheretherketone, 30% Carbon Fiber Reinforced, Injection M olded 1.42 g/cc 32 ksi 1% 1,798 ksi 7.8 m(ºF)-1 6.4 Btu/ft-h-°F

M . A. Hanna Edgetek CTX-1110 Polyetheretherketone with Carbon Fiber 1.407 g/cc 30 ksi 2% 1,305 ksi 7.9 m(ºF)-1 6.5 Btu/ft-h-°F

M . A. Hanna Edgetek PK-30CF/000 Polyetheretherketone - 30% Carbon Fiber Reinforced 1.42 g/cc 30 ksi 1.5% 2,596 ksi 8.0 m(ºF)-1 6.5 Btu/ft-h-°F

Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced 1.41 g/cc 32.6 ksi 2% 1,885 ksi 7.8 m(ºF)-1 6.4 Btu/ft-h-°F

Victrex PEEKTM 450CA30, 30% Carbon Fiber Reinforced 1.41 g/cc 32.5 ksi 2% 1,885 ksi 7.8 m(ºF)-1 6.4 Btu/ft-h-°F

Manufacturing Processes

• Current Processes

• Alternatives– Roll forming

• Metal

• Shorter manufacturing time

– Injection Molding• Requires plastic as material

– Compression Molding• Requires plastic as material

• Cost of Process– Tooling cost

– Raw material cost

Casting Machining Forging Plating Surface Finishing Precision Inspection132796-1 (handle) X X X X X117052-999 (housing) X X X X119922-997 (actuator) X X X X117067-999 (collar) X X X X

Machining• Current Sequence

– setting fixture setting tooling checking programs inserting casted parts remove finished parts inspection storage

• Alternatives– net-shape forming

Advantages Disadvantages virtually no material waste lower energy product because material

is Mold parts into high-precision finished parts diluted by the binding polymer lower manufacturing cost by saving machining decreased corrosion resistance time lack of high quality, reasonable-cost power Ideal for complex shapes price for general alloys average $40/pound

– outside processing (O/P) in foreign countries Outside processing in foreign countries has several disadvantages: present currency exchange rate between Europe and America limits the benefits complexity of certain parts makes O/P impossible. Reliability and quality control becomes a problem. instability of foreign work force – machining optimization

install software to provide a better integrated CNC production facility change tooling and carbide brand and type install high pressure coolant systems to increase production efficiency and extand tool life time

Functional Design

• Existing– A spring-loaded release lever that

extends and rotates the outside handle assembly from inside the door.

– A spring-loaded outside handle assembly that seats flush in the housing when stowed for flight, and extends under spring load for use when the trigger or release lever is pushed.

– The flush handle latch assembly consists of one each: release lever, rod end, cover, actuator rod (not shown), outside handle assembly with integral spring-loaded trigger, trigger lift assembly actuator fitting, inner support, and a collar.

– Components are secured by attaching hardware and pins retained by sealant.

– Elastomer quad rings in the actuator assembly, inner support, and collar provide environmental and pressure seals.

– Qualification

Technical Specifications

DESCRIPTIONProperty SpecificationsManufacturer Hartwell Corporation (CAGE 83014)Part Numbers

Hartwell Corporation H3414-9,-23,-25,-29,-33Canadair 601R38132-7, 601R38132-9, 601R38132-11,

601R38132-11, 601R38132-13Nomenclature Flush Handle Latch AssemblyFUNCTIONAL CHARACTERISTICSHandle Travel 44 to 46 Degrees (counterclockwise)Outside Handle Extension to Operating Position 1.45 to 1.55 in. (36,83 to 39,37 mm)Torque Required to Turn Handle 10 in-lbs (1,13 N.m) maximum at 55 to 75*F (13 to 24*C)Force Required to Stow Outside Handle 15 lbs (6,8 kg) maximumPressure Difference Without Leakage 18.5 psig (123 kPag) maximumPHYSICAL CHARACTERISTICSOverall DimensionsHeight 8.81 in. (223,77 mm)Width 7.57 to 7.87 in. (192,28 to 199,89 mm)Length 15.17 to 15.28 in. (385,32 to 388,11 mm)Weight 6.6 lbs (3,0 kg) maximum

Functional Design

• Alternatives– fewer parts

– simplified assembly

– new materials

– new manufacturing processes

• Testing

• Wearability

Design Concepts

1. Materials

2. Manufacturing

3. Machining Optimizations

4. Functional Design

Design Concept 1 Materials

• Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced instead of aluminum alloy for collar and flush handle housing

• Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced– Cost

• Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced are packaged in 55.1 lb boxes

1 - 11 boxes - $ 40.75 /lb

12 - 23 boxes - $ 38.50 /lb

24 + boxes - $ 36.50 /lb

• Advantages– Saving approximately $31 per collar ( 75 % material cost )– Saving approximately $65 per housing ( 73% material cost )– Lighter Weight

• Disadvantages– Reducing the tensile strength in 20%– Brittleness– Temperature Range ( -85°F - 599 °F )

Collar

Flush Handle Housing

Design Concept 2Manufacturing

• Manufacturing Method

• Change in manufacturing cost (quantity of 100 per year)

– first year :

– next year :

–

–

Casting (Current) Injection Molding (Alt.)

Housing(117063-9)

Tooling charge: $14,100.00Material: $85.75

Machining: $75.60

Tooling charge: $20,000.00Material: $20.00Machining: $0.00

Collar(117067-5)

Tooling charge: $4,500Material: $41.30

Machining: $28.36

Tooling charge: $7,000.00Material: $10.00Machining: $0.00

• Advantages– No machining required

– No surface finish required

– No plating required

– Lower material cost

• Disadvantages– Material change required

– Investment in tooling charge

Casting vs. Injection Molfing

0

50

100

150

200

250

300

350

1 2 3 4 5

Year

Cos

t ($)

TMC (Alt)

TMC (curr)

increase 99.68$

36.2860.751030.412075.85100

700020000

decrease 01.201$

36.2860.751030.412075.85

TMCin decrease %4.1546.1302$

01.201$

charges toolingmoldinginjection

theovercome tomonths 4year 1 years 34.101.201$

99.68$1

Design Concept 3 Machining Optimizations

Machining optimization: software

Integrated machining system for production facility from GE Fanuc VisualDocs - Designed to replace paper and improve productivity on the shop floor, this software can provide operators with access to virtually any information on the floor, helping them tap into the combined operating knowledge of the company. VisualMEM - Designed to help manufacturers gather machine performance information on the floor, VisualMEM (Machine Event Monitoring) records each event that takes place on a machine and places that information in a database for further analysis. 10% production improvement typical when implemented. VisualDocs

Visual MEM

Machining optimization: hardware

change tooling and insert type or brand

For the machining of 17-4 PH stainless steel and A356.0 T61 Al alloy, two alternative

tooling inserts from Kennametal are suggested:

For 17-4 PH stainless steel For A356.0 T61 Al

alloy

insert geometry: MM-MR MS

recommended Grade: KC9025 KD100

feed rate: 0.0255 in 0.0186 in

depth of cut: 0.2102 in 0.1046 in

install EV2000 high pressure coolant system produced by chipblaster (unit price: $15,695)

machining time and tool life time will increase 30% minimum

cost saving study: - 8.477 hrs of machining labor per piece under regular coolant system

- overhead rate of 4.03

- assume an average labor rate of $15.00/hr

- assume 30% production efficiency and tooling life gain by using high

pressure coolant system

(8.477*15*4.03) - (8.477*.70*15*4.03) = 153.73 ----------------------------- cost saving per piece

15,695 / 153.73 = 102.09------------------------------ pay back after 103 units

153.73*100 = 15,373------------------------------ machining labor saving per

100 units

EV 2000

Design Concept 4Design

• Design Alternatives

– Trigger button

– Trigger lift assembly

– Flush handle

– Housing (rivet inserts)

– Collar (rivet inserts)

• Advantages– 10 Fewer Parts– Cost Reduction $43.80– Weight Reduction

• Disadvantages– Testing– Modification

Link Assembly

Trigger

Selection Matrix

Design Concepts 1 (Materials) 2 (Manufacturing) 3 (Machining) 4 (Design)

Specifications

Cost 2 2 1 1

Plating 1 1 1 1

Durability 2 1 1 1

Functionality 1 1 1 2

External Geometry 1 1 1 1

Weight 2 2 1 2

Thermal Performance 0 0 1 1

Total 9 8 7 9

Recommendation

• Replace collar and housing material with PEEK, 30% carbon reinforced

• Redesign consistent with the material change to reduce the overall cost

• Use injection molding instead of casting & machining

• Remove link assembly (130331-5)– Due to qualification by similarity to H3412-1 in which the link assembly is not included*

*Independent Testing Laboratories, Inc. Test Report No. TR9500

Timeline

7th week 8th week 9th week 10th week final week

Summary• Analyzed Cost Auditor Quote

• Identified Four Most Expensive Parts

– Housing, Handle, Collar, and Actuator

– 55% of total manufacturing cost

• Researched on:

– Alternative Materials

• PEEK (Polyetheretherketone)

• PAEK (Polyaryletherketone)

• NORYL

• ULTEM

– Alternative Manufacturing Processes

• Injection molding

• Roll forming

• Compression molding

– Alternative machining processes

• Net-shape forming

• Outside processing (O/P)_

• Machine optimization: hardware and software

– Alternative designs

• Down selection

• Proposed design

– Replace Aluminum Alloy with Victrex PEEKTM 150CA30, 30% Carbon Fiber Reinforced in housing and collar

– Injection molding of collar and housing instead of casting and machining

• Wearability good for the proposed design

• Cost saving: ( $1,302.46 v.s. $1,071.45)

– $231.01 decrease in total manufacturing cost