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Clearance adjustment:Shims for Cost Reduction
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Clearance adjustment:Shims for Cost Reduction
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
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Content of Presentation
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Cost Reduction Over the Whole Process Chain
Clearance adjustment:Shims for Cost Reduction
DESIGN
MAINTENANCE PURCHASING
LOGISTICS(SHIM RING
MANUFACTURING)
SUB ASSEMBLY + BEARING MOUNTING
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Key information aboutGeorg Martin GmbH
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Clearance adjustment:Shims for Cost Reduction
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Clearance adjustment:Shims for Cost Reduction
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Key information aboutGeorg Martin GmbH
Clearance adjustment:Shims for Cost Reduction
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)
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Example 1/2Tapered Roller BearingsIn MetallurgicalWork Rolls
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Laminated Shim Ring Between Housing andCover
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Example2/2Ball BearingsIn Gearboxes
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Assembly and Total Cost of Ownership Assembly & TARGETS - Objectives
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Assembly and TCO Choice of Material Structures Assembly TARGETS
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=
=
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Practical Design TCO / Complete Life Cylce Cost
CHEAP?
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Logistic (& Manufacturing) CostsOver the Whole Process Chain
Clearance adjustment:Shims for Cost Reduction
Solid Shim Rings With Fixed Thicknesses:
- Stock Control
- ChaoticConsumption(ConsumptionDriven)
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Manufacturing and Logistic CostOver the Whole Process Chain
Clearance adjustment:Shims for Cost Reduction
ProductionPlanning
Pre-Assembly&
Final Assembly
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ProductionPlanning
Pre-Assembly&
Final Assembly
Manufacturing CostOver the Whole Process Chain
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Influences of CostConclusion: Overall Approach & Choice
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Technical Requirements
Environment Loads Corrosion Light weight …
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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“
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Clearance adjustment:Shims for Cost Reduction
M-Tech®P „Packet“Con‘s:
- Sealing aspect
- Very Tough Load conditions
- Shear forces
Material Structures Differentiate Aspects: P
„P“
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Clearance adjustment:Shims for Cost Reduction
M-Tech®P „Paket“Layer Connections:
New:Laser Welded Connection
Material Structures Differentiate Aspects: P
„P“
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Clearance adjustment:Shims for Cost Reduction
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
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M-Tech®L „Laminated“Con‘s:
- Dynamic Loads
- Temperature >> 200°C
- Harsh Friction
- Intense Shear Forces
„L“
Material Structures Differenciate Aspects: L
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M-Tech®L „Laminated“Layer Connections:
Fully Laminated for Temporarily Connection
Glued for PermanentConnections BetweenLaminated Sections On Solid Rings Elements
„L“
Material Structures Differenciate Aspects: L
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„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
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Clearance adjustment:Shims for Cost Reduction
„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
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Design Tips for Assemblies Where to Use Which Shim Type
Clearance adjustment:Shims for Cost Reduction
One (orSeveral) WasherOrShim
One Full Shim RingOrOne Split Shim Ring
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Design Tips for Assemblies Where to Use Which Shim Type
Clearance adjustment:Shims for Cost Reduction
„S“
„L“( )
Directly Near to the Bearing: Can Bring Wearand FrictionProblems Over Life Time
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Design Tips for Assemblies Where to Use Which Shim Type
Clearance adjustment:Shims for Cost Reduction
„P“
„L“
„S“
Ideal Placement With No FrictionAs Almost StaticLoad Condition. No InterferenceWith Bearing.
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Shims… a „last“ aid for designers ?? or…
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Clearance adjustment:Shims for Cost Reduction
Shims… Are A Strategic Approach to Reduce Over all Process Costs !
DESIGN
MAINTENANCE PURCHASING
LOGISTICS(SHIM RING
MANUFACTURING)
SUB ASSEMBLY + BEARING MOUNTING
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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
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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
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Many Thanks for your Attention,
ENJOY YOURSELF REDUCING OVERALL PROCESS COSTS !
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Mr. Christoph Martin + 49 151 [email protected]
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Back Up Slides…
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Back-Up Slides Material lists Mechanical pressure resistance
information Example Calculation Temperature Information
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Material ListsSolid and Packed Materials
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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
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AppropriatePressure Load Types
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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
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Temperature IndicationsFor Different Material Structures
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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
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Pressure ResistanceFor Different Material Structures
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http://www.georg-martin.de/uploads/Produktspezifikationen/ENG/02%20martin_strength_values.pdf
Subject to changes. Depending on assembly conditions tests areimperatively suggested. All information and visuals belong to
named owner or Georg Martin GmbH
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Pressure ResistanceExample of Static Load Calculation
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http://www.georg-martin.de/uploads/Produktspezifikationen/ENG/02%20martin_strength_values.pdf
Subject to changes. Depending on assembly conditions tests areimperatively suggested. All information and visuals belong to
named owner or Georg Martin GmbH