This work aims to identify the challenges of the process of cutting pipe samples with the current cutting machine at Sandvik Materials Technology SMT. The purpose is to create a design that avoids the identified problems.
The design aims to improve the quality of the piece that is cut from the pipe before examining it by the material testing machine (stress /strain testing) that checks the quality of the produced tubes of Sandvik Factory before selling.
The new design is expected to reduce the number of defective pieces. It will also make the work easier, faster, and more precise. Currently, the pipes are of various diameters and lengths are secured by clamps driven by pneumatic cylinder. These clamps hold a pipe by each end. Then the pipe is placed on a water table where a water jet cuts the test piece.
After observation and interviewing with customers, the problems were identified. We realized that the existing mechanism was very complicated, and a new mechanism was needed.
Three proposals were developed. These proposals were evaluated by using a Pugh matrix and the best proposal was selected.
The chosen solution requires : a balanced movable table which moves up and down by a waterproof electrically- linear actuator, a V-shaped piece fixed to the table that fits pipes of various diameters and lengths, a pneumatic cylinder which clamps the pipe and secures it in place.
An alternative solution was to improve the current fixture, but the customer want-ed to focus on developing a completely new concept. An important factor in the concept development was that the fixture must be able to function in an unique environment of a water bath with sand. This environment entails major limitations regarding the choice of materials and machine elements. Two support legs were developed to reduce the bureau loss effect when the table goes up or down due to the weight not evenly distributed on the table surface. During the development concept, the need was identified for a sensor that can ensure that the table is lowered to the correct level. Selection of the sensor requires automation knowledge, this is why it was eliminated from the work. This new mechanism ensures securing the pipe in place and reduces the number of required actions in the process. This leads to reduction of the defects in the test piece. The new design is simpler, faster, requires less space and is more precise.