This document discusses two senior design projects for tractor components: an exhaust valve cage and an intake/exhaust manifold. It provides details on the manufacturing plans, processes, locations, tools, and metallurgical specifications for producing the parts. It also mentions predicted defects for the exhaust valve cage and inspection processes and tools for the intake/exhaust manifold. Budget and schedule information is briefly referenced at the end.

1. Tractor Components Senior Design Project Spring ‘07 Charlie Tullis

2. Part #One: Exhaust Valve Cage 1914 McCormick 8-16 Mogul Tractor Problem: Customer missing part

3. Part #One: Exhaust Valve Cage Original International Harvester Corp. Final Part prints

4. Part #One: Exhaust Valve Cage

5. Part #One: Exhaust Valve Cage

6. Part #One: Exhaust Valve Cage Predicted Porosity

7. Part #One: Exhaust Valve Cage Manufacturing Plan Part Exhaust Head Process Sub- Processes Location Tools Core making Filling Core wash repair Foundry Core Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring Closing Foundry Patterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Out Source Sand Blaster Grinders Paint Equip.

8. Part #One: Exhaust Valve Cage Metallurgy Total Carbon =3.57% Silicon =3.37% Cu =? Cr =.02% Mo =.01% P =.89% Desired Brinell Hardness HB=170-200 Actual HB= 321

9. Part #One: Exhaust Valve Cage Grey Iron 80% type A graphite 20% type D&E

10. Part #One: Exhaust Valve Cage Molding

11. Part #One: Exhaust Valve Cage Molding

13. Part #One: Exhaust Valve Cage Pouring

14. Part #One: Exhaust Valve Cage Pouring

15. Part #One: Exhaust Valve Cage Shake Out

16. Part #One: Exhaust Valve Cage Cleaned Parts

17. Part #One: Exhaust Valve Cage Casting Defects Gas defect only ( Blow)

18. Part #Two: Intake/Exhaust Manifold

19. Part #Two: Intake/Exhaust Manifold Manufacturing Plan Part Intake/Exhaust Manifold Process Sub- Processes Location Tools Core making Filling Assembly Core wash repair Foundry Core Boxes Sand Mixer daub paste wash Molding Molding Mold washing Coring Closing Foundry Patterns Wash Files Paste Chaplets Clamps/Weights Pouring Foundry Cleaning/ Inspection Foundry/Out Source Sand Blaster Grinders Paint Equip.

20. Part #Two: Intake/Exhaust Manifold Metallurgy C =3.66% Si =1.6% Ni =0.9% Cr =0.85% Mo =0.65% Cu =0.35%

21. Part #Two: Intake/Exhaust Manifold Original Manifold Manifold Pattern Follow Board

22. Part #Two: Intake/Exhaust Manifold Exhaust Core Boxes ( under construction)

23. Part #Two: Intake/Exhaust Manifold Intake Core blank

24. Part #Two: Intake/Exhaust Manifold Pin Core Box

25. Inspection Process Solid walls Inclusions Surface defects (rat tails, buckles, burn on) Pin holes Cold laps Inspection tools Visual Pressure test Ultrasonic imaging

26. Budget

27. Schedule