Summary
Toolcraft, renowned for its precision manufacturing solutions, designed and manufactured a custom shaft for Dixie Sternwheeler. This shaft is essential for the vessel’s propulsion system, ensuring high performance and durability. This case study covers the specifications, applications, manufacturing process, and quality control measures implemented to deliver this critical component.
Project Overview
- Product: Shaft
- Industry: Marine Propulsion
Overall Specifications
- Material: A311 Class B Stressproof® Turned Ground and Polished Steel Round Bar
- Stock Dimensions: 2-7/16″ diameter x 118-1/2″ length
- Tolerance: Maintained within +/- .005″ on machined keyways
Uses and Applications
The shaft is utilized in:
- Propulsion System: Converting rotational motion from the engine into thrust for the paddlewheel.
- Marine Applications: Ensuring smooth and efficient operation, crucial for vessel maneuverability and performance on the water.
The shaft is designed to handle high torque and rotational forces, ensuring reliability under heavy load conditions. It can withstand the harsh marine environment, providing long-term durability and minimal maintenance. Toolcraft’s facility supports both small and large batch productions, ensuring scalability and flexibility.
Quality Control
Toolcraft’s quality control procedures ensured the shaft met stringent standards:
- Dimensional Inspection: Used certified gage blocks & gage pins, a digital height gage and other inspection equipment.
- Material Testing: Conducted metallurgical tests to confirm material properties.
- Surface Finish Inspection: Ensured the polished surface met the required roughness and finish specifications.
- Final Inspection: Thorough final inspection to validate overall quality and readiness before delivery.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Design and Engineering
Toolcraft’s engineering team collaborated with Dixie Sternwheeler to finalize specifications. Advanced CAD software was used for precise design and compatibility.
Material Selection and Procurement
A311 Class B Stressproof® Turned Ground and Polished Steel Round Bar was selected for durability and precision. Sourced from certified suppliers to ensure consistent quality.
Precision Machining
CNC lathe was employed to cut and shape the raw material to exact dimensions. Multi-axis machining centers created keyways and threads necessary for assembly.
Heat Treatment
The shaft underwent heat treatment to enhance its mechanical properties, including strength and toughness.
Surface Treatment
The shaft’s surface was polished to a mirror finish, providing excellent corrosion resistance and reducing friction during operation.
Assembly and Integration
Components were meticulously inspected and prepared for integration into Dixie Sternwheeler’s propulsion system.
Conclusion
Toolcraft’s precision manufacturing and commitment to quality resulted in the successful development of the shaft for Dixie Sternwheeler. This component enhances the capabilities of the vessel’s propulsion system, providing reliable and efficient solutions for marine applications. Through meticulous design, manufacturing, and quality control processes, Toolcraft delivered a robust and accurate shaft tailored to meet the specific needs of Dixie Sternwheeler.