slacfilespast_work99_00Vikash_GoyalCopperQFDslac.ppt.pptVIP

ME 317 - Total Product IntegrationProject 慏iamond Tool Life? Application Specific Quality Function Deployment For Copper Vikash Goyal Autumn?999 Agenda Introduction - Motivation ; Diamond tool life and the copper - Background ; Copper Terminology and Practices Project Description - Scope, and applications - Methodology for material QFD QFD flow down Matrices Case Study for applications at SLAC Summary Introduction; Motivation for Copper QFD Catastrophic failure of diamond tool observed during diamond turning of copper cells at KEK LLNL. Substantial cost implications. Debate over the possible reasons (tool quality crytal orientation, diamont turning process control, impurities in copper material) in absence of adequate data. Perhaps the carbon inclusions in copper lead to tool failures. No research or information about Carbon impurity in copper. Extensive use of High Purity Copper at SLAC. Copper of different grades is used for different applications (Klystrons, Waveguides, cells) Class designations are further specified within a grade. Electroplated copper is less pure than OFE copper used in SLAC but machines well and without tool failure. Thus, definition of material purity is application specific and needs to be probed. Introduction; Copper Terminology and Practices The Processes Introduction; Copper Terminology and Practices ASTM Designations Similar Composition for Wrought (C1xxxx to C7xxxx) and Cast (C8xxxx and above). Initial Material Selection possible without regard to manufacturing process. Coppers - oxygen free(C10xxx), tough pitch(C11xxx), Others (C12xxx to C15xxx) High Copper Alloys - 96% but 99.3% (C16xxx to C19xxx) Brasses - Copper Zinc (C20xxx to C49xxx) Bronzes - Copper Tin (C50xxx to C661xx) Cupro-Nickels - Copper Nickel (C70xxx to C79xxx) Project Description Scope : Pure Copper ( 99.3% Cu) Users : Design and Manufacturing Engineers Applications : Busbars, Bus-conductors, Auto gaske