Clearance adjustment: Shims for Cost Reduction for Clearance... · 2016. 7. 5. · Sum –Up 2/2:...

Clearance adjustment:Shims for Cost Reduction

All information and visuals belong to named owner or Georg Martin GmbH

Shim Rings:

Explanation of Cost Reduction Over the Whole Process Chain

FLEXIBLE Material Structures:

Why to Differentiate Shim Types

Design Tips for Assemblies:

Where toUse Which Shim Type

Content of Presentation

Cost Reduction Over the Whole Process Chain

DESIGN

MAINTENANCE PURCHASING

LOGISTICS(SHIM RING

MANUFACTURING)

SUB ASSEMBLY + BEARING MOUNTING

Key information aboutGeorg Martin GmbH

Founded: 1945

Family owned

95 Employees

Turnover: 10,6 Million Euro

Product & Services: Metal Forming Parts, Sub Assemblies And Shims

USP: Laminated Shim Manufacturing Germany

Industry Sectors: General Industries, Mechanical Power Transmission & Aviation

Approvals: AIRBUS GROUP, Rolls Royce, UTC, SAFRAN, Voith, div. Gear Box Manf.

Certifications: EN 9100 (Aviation) & ISO 14001 (Environment)

Example 1/2Tapered Roller BearingsIn MetallurgicalWork Rolls

Laminated Shim Ring Between Housing andCover

Example2/2Ball BearingsIn Gearboxes

Assembly and Total Cost of Ownership Assembly & TARGETS - Objectives

Assembly and TCO Choice of Material Structures Assembly TARGETS

Practical Design TCO / Complete Life Cylce Cost

CHEAP?

Logistic (& Manufacturing) CostsOver the Whole Process Chain

Solid Shim Rings With Fixed Thicknesses:

- Stock Control

- ChaoticConsumption(ConsumptionDriven)

Manufacturing and Logistic CostOver the Whole Process Chain

ProductionPlanning

Pre-Assembly&

Final Assembly

ProductionPlanning

Pre-Assembly&

Final Assembly

Manufacturing CostOver the Whole Process Chain

Influences of CostConclusion: Overall Approach & Choice

Technical Requirements

Environment Loads Corrosion Light weight …

M-Tech®P „Paket“Pro‘s:

Lift Foils With Fingers High temperatures Fast Handling Free Combinations Different Materials Different Thicknesses Min. 0,025 Curved Surfaces Demand Driven One Piece Flow

Material Structures Differentiate Aspects: P

„P“

M-Tech®P „Packet“Con‘s:

- Sealing aspect

- Very Tough Load conditions

- Shear forces

„P“

M-Tech®P „Paket“Layer Connections:

New:Laser Welded Connection

„P“

M-Tech®L „Laminated“Pro‘s:

MARTIN Peel Tool® Sealing Advantages Demand Driven High Reliablity Solid Sections Possible Different Foils Possible Min. Foils: 0,010mm Easy to Measure Demand Driven One Piece Flow

„L“

Material Structures Differenciate Aspects: L

M-Tech®L „Laminated“Con‘s:

- Dynamic Loads

- Temperature >> 200°C

- Harsh Friction

- Intense Shear Forces

„L“

M-Tech®L „Laminated“Layer Connections:

Fully Laminated for Temporarily Connection

Glued for PermanentConnections BetweenLaminated Sections On Solid Rings Elements

„L“

„S“

Material Structures Differenciate Aspects: S

M-Tech®S „Solid“Pro‘s:

All mechanical Load Types Temperatures >> 200°C Parallelity Demands Shear Forces Single Foils Thickness

min. 5 µm

„S“

Material Structures Differenciate Aspects: S

M-Tech®S „Solid“Con‘s

- Process Costs- Maintenance Processes- Hidden Costs- Foil Handling in Assembly- Measuring Foils- Consumption Driven- Or Expensive Single Piece

Production

Design Tips for Assemblies Where to Use Which Shim Type

One (orSeveral) WasherOrShim

One Full Shim RingOrOne Split Shim Ring

„S“

„L“( )

Directly Near to the Bearing: Can Bring Wearand FrictionProblems Over Life Time

„P“

„L“

„S“

Ideal Placement With No FrictionAs Almost StaticLoad Condition. No InterferenceWith Bearing.

Shims… a „last“ aid for designers ?? or…

Shims… Are A Strategic Approach to Reduce Over all Process Costs !

DESIGN

MAINTENANCE PURCHASING

LOGISTICS(SHIM RING

MANUFACTURING)

SUB ASSEMBLY + BEARING MOUNTING

Sum – Up 1/2:

Practical and Easy Design Processes

Sum Tolerances of Bearings and Housing Will be Nullified

Without Increasing the Production Cost of the Other Components

Non-Automated Assemblies Will be Fast and Easy

Assembly Process Can Take Place Regardless of the Location

Reasons for Laminated and Paketed Rings

Sum – Up 2/2:

No Invest in Machines

Indirect Labor and Process Cost Reduced

One Piece Flow

Demand Driven instead Consumption (Chaotic) Driven Demand

Easy Maintenance Assembly Processes

Customer Satisfaction by Down-Time Reduction

Reasons for Laminated and Paketed Rings

Many Thanks for your Attention,

ENJOY YOURSELF REDUCING OVERALL PROCESS COSTS !

Mr. Christoph Martin + 49 151 16142488C.Martin@Georg-Martin.dewww.Georg-Martin.de

Back Up Slides…

Back-Up Slides Material lists Mechanical pressure resistance

information Example Calculation Temperature Information

Material ListsSolid and Packed Materials

http://www.georg-martin.de/uploads/Produktspezifikationen/04%20Materialspezifikation_M-Tech_S.pdf

Laminated Materials:http://www.georg-martin.de/uploads/Produktspezifikationen/05%20Materialspezifikationen_M-Tech_L.pdf

AppropriatePressure Load Types

Mechan. Load/Product type

Static Dynamicallyswelling

Dynamicallyalternating

M-Tech®L andLaminum® -

M-Tech®S (*)

M-Tech®P andLamivario® (*)

Subject to Changes. Depending On Assembly Conditions Tests Are Imperatively Suggested. All information and visuals belong to

named owner or Georg Martin GmbH

Temperature IndicationsFor Different Material Structures

Temperature

Product type

Up to 100°C Up to 200°C Over 200°C

M-Tech®L and

Laminum® Only

steel types-

M-Tech®S /(*) / (*)

M-Tech®P and

Lamivario® /(*) /(*) /(*)

Subject to changes. Depending on assembly conditions tests areimperatively suggested. All information and visuals belong to

Pressure ResistanceFor Different Material Structures

http://www.georg-martin.de/uploads/Produktspezifikationen/ENG/02%20martin_strength_values.pdf

Pressure ResistanceExample of Static Load Calculation

http://www.georg-martin.de/uploads/Produktspezifikationen/ENG/02%20martin_strength_values.pdf

Clearance adjustment: Shims for Cost Reduction for Clearance... · 2016. 7. 5. · Sum –Up 2/2:...

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