The casting of parts by pouring molten metal into a mold has been a popular and efficient way to make parts for some time. However, despite the wide spread use of this technology, it can still be a time intensive and costly endeavor for one to undertake if the proper equipment and facilities are not present. In addition, even in the event that the resources are readily available, it is still remarkably likely that a casted part will be of substandard quality or will have a disqualifying defect. It is for this reason that our team was solicited by Dr. P.A. Simionescu to construct a device that will allow the user to use the centrifugal casting method to make castings.

1. Texas A&M University – Corpus Christi
School of Engineering and Computing Sciences
Capstone Project Plan
s
TEAM:
Derek Veuleman
Samir Abusetta
Michael Frazier
Shumeng Wang
Shehryar Niazi
Advisor: Dr. P.A. Simionescu
MEEN 4340.001 Project Management – Fall 2013
Professor: Dr. Ruby Mehrubeoglu
Date: November 9th, 2013
Executive Summary:
The casting of parts by pouring molten metal into a mold has been a popular and efficient way
to make parts for some time. However, despite the wide spread use of this technology, it can
still be a time intensive and costly endeavor for one to undertake if the proper equipment and
facilities are not present. In addition, even in the event that the resources are readily available, it
is still remarkably likely that a casted part will be of substandard quality or will have a
disqualifying defect. It is for this reason that our team was solicited by Dr. P.A. Simionescu to
construct a device that will allow the user to use the centrifugal casting method to make
castings.

2. Table of Contents
3. LIST OF FIGURES…………………..………….…………………………………..….….4
4. LIST OF TABLES…………………...…...…………………………………….…………..5
5. INTRODUCTION………………………………...…………………………………………6
6. BACKGROUND………………………………..…………………………………..……....7
7. DESIGN......................................................................................................................8
7.1 Design Criteria………………………………...……………………….....…8
7.2: Design Alternatives…………..………………………………..…….……..9
7.3 Updated Design………...….………………………………………………..9
8: FEASIBILITY ANALYSIS AND PROJECT JUSTIFICATION…….….….………....13
8.1: Economic……………………………..……………………….………......13
8.2: Environmental…………….………………………………………….……13
8.3: Sustainability……………………………..…………………………….....14
8.4: Manufacturability…………………………..……………………………..14
8.5: Technical………………………………….……………………...........…14
8.6: Ethical………………………………….…...…………………..…………14
8.7: Social………………………………….…...…………………………..….14
8.8: Health and Safety…………………….…………………………….....…14
8.9: Political…………………………………..……………………………..…15
9: PROJECT PLAN……………………………………...……….……………………......15
9.1: Plan of Work, Action/Activity Plan..............................................…...15
9.2: WBS and Linear Responsibility Chart………………….…………..….17
9.3: Network Diagram……………………………………………………......19
9.4: Timeline………………………………….……………….……...........…20
9.5: Resource Allocation, Loading and Leveling…………….……...….…20
2

3. 9.6: Test and Evaluation Plan…………………………………….……..….21
9.7 Risk Management Plan………………………………………………....21
9.8: Business Plan……………………………..……………………….....…24
10: COST ANALYSIS AND JUSTIFICATION…………………………………..……..…25
11: IMPLEMENTATION……………………………………...…………………...……......26
12: EXPECTED RESULTS AND DELIVERABLES..............................................…...26
13: EVALUATION PLAN………………….……………………………………………......27
14: MONITORING AND CONTROL PLAN……………………………………….………27
15: AUDIT RESPONSE AND TERMINATION PLAN…………………………………...28
16. RELEVANT STANDARDS..............................................................................…...26
17. PROFESSIONAL GOALS AND NECESSARY SKILLS...……….….…………......29
18 CONCLUSIONS................................................................................................…...29
REFERENCES………..………...……………………………………………………….28
3

4. List of Figures
6.1: Vertical Axis Centrifuge vs. Horizontal Axis Centrifuge…………….…….………......……7
7.1: A CAD sketch of the preliminary design…………………………………….……....……….8
7.2: A CAD sketch of the updated design with reference dimensions (inches)…...................9
7.3: A photo showing the bottom view of the final design………………………………....…..10
7.4: A photo showing the shape and size of the pump diffuser ring (inches)……………….10
7.5: A photo showing the profile of the pump diffuser ring…………………………………….11
7.6: A 3d model of the pump diffuser ring……………………………………………………….11
7.7: A draft angle analysis of the diffuser ring for mold making……………………………….12
7.8 A 3D Model of the mold cavity for the diffuser ring………………………………………...12
9.1: An AON diagram for summary tasks only……………….……………………...………….19
9.2: A Gantt chart diagram showing the current phase tasks and all summary tasks……...20
4

5. List of Tables
8.1: Parts list and budget…………………………………………………………………………13
9.1: A table showing the action plan for the project…………………………………………...16
9.2: A table showing the work breakdown structure for the project…………………….……17
9.3: A RACI matrix to complement the WBS table…………………………………………….18
9.4: A qualitative risk analysis table……………………………………………………………..22
9.5: A quantitative risk analysis table……………………………………………………………22
9.6: A risk response planning table……………………………………………………………...23
10.1: Bill of Materials…………………………………………………………………………...….25
14.1. Earned Value Analysis……………………………………………………………………...28
5

6. 5. Introduction
Vertical Casting Centrifuge can be used to make parts that are hard to find with almost
perfect geometry. If working with precious metals one can never afford to have any scrap; the
casting centrifuge solves this problem. The report goes over the entire project proposal detail.
Detailed information is included regardingbackground, design, feasibility analysis, cost analysis,
project plan, implementation, expected results and deliverables, evaluation plan, monitoring and
control plan, termination plan, the skills that were required and the conclusions.
The casting device that our team plans to make rotates about the vertical axis hence the
name Vertical Axis Centrifuge. The drum rotates and the molten metal moves towards the walls
of the drums because of the centrifugal force. As the metal cools down it solidifies to the shape
required by the mold. The device that we plan to make rotates at a high rpm, which will make
the parts made have minimal defects. As the drum rotates faster, more centrifugal force will be
present that makes the metal grains to be densely packed together.
We preferred making vertical axis centrifuge to the horizontal axis centrifuge due to different
reasons. In a horizontal axis centrifuge when the mold reaches the top of the orbit it has gravity
pulling it down because of which we need a higher rpm to keep the centrifugal force higher at
that point. The gravity directly opposes the centrifugal force. To generate a better part with
minimal defects, higher centrifugal force is required. This way we can make parts that can meet
industry standards. Since we also plan this casting machine to be capable of designing car
spare parts, we want it to be really precise with accuracy. Vertical axis centrifuge has exactly
the same gravitational force being acted on the entire mold. The properties and the finish stay
consistent throughout the part. Vertical Axis Centrifuges are often used for making parts that
have low length-to-diameter ratio such as rings, bearings, coil etc. Horizontal Axis Centrifuges
on the other hand are used to make parts that have high length-to-diameter ratio such as pipes,
tubes, bushings, cylindrical liners etc.
We had several motivations that lead us to designing this casting machine. One of the group
members has a 1987 Mercedes Benz 260E and he has an idea how expensive it can be to get
spare parts for old cars and machines. We really want to make acquiring obsolete and
expensive parts easier for the consumers. Imagine how amazing it would be if a Ferrari owner
could cast his own exhaust sitting in a small machine shop which otherwise would cost
thousands of dollars.
A lot of exotic materials go to waste whenever they are cut into the desired shape. The
casting machine we’re designing will have no wastage of metal at all. We’ll heat up the metal
and pour it in the mold, which will then solidify as the drum rotates.
This machine could also be very useful for small business like jewelry shops. Jewelry shops
have to work with fabricating different shapes on everyday basis. The casting machine specially
comes in handy when you want to create a same part over and over again. For instance if you
the company is wanting to make a chain connection over and over again, they just have to
design the mold once. The mold will have to be made for different shapes to be casted.
Designing the casting machine is also going to help our universities’ engineering
department’s lab a lot too. We don’t have a single casting machine. Whenever a student wants
to get a desire part they have to either cut it or get it casted from the art department. This
casting machine could help the future engineering students immensely.
This report has more details on the design, economic analysis, accomplished work, and the
entire project plan in general. We’ve done in-depth research and can really make this casting
machine to work out well.
6

7. 6. Background
Centrifugal casting is also known as rotocasting and Alfred Kupp invented it in 1852. He
used it to cast steel tires for railway wheels. The casting technique is known for high quality
mechanical finishes. The motor spins within a range of 300-3000rpm making the casted parts
have almost perfect geometry. The force generated by the rotating of the motor is much more
than that of the gravitational force that gives the parts dense molecular structure.
Different casting techniques are suitable for different kinds of parts desired. Centrifugal
casting is preferred for generating cylindrical objects. Parts like pipe, bushings, and gun barrel
are all centrifugally casted. As mentioned in the introduction earlier, there are two kinds of
centrifugal casting machines, the horizontal axis and the vertical axis.
It’s not just the desired shape that leads us to pick between vertical or horizontal casting but
it is also the metal that matters. Different molten metal behave differently while being rotated.
The force throughout the molten metal is constant in vertical axis centrifuge unlike in a
horizontal axis where the gravitation force plays a major role. Also another way the molten
behaves differently is that the metal slips in a horizontal axis centrifuge. Naturally the gravity
pulls it down and keeps it from being rotated along with the rotating drum. Hence in a horizontal
axis centrifuge the molten has to be accelerated to the final speed increasing the inertia of the
metal. Vertical Axis Centrifuge can also have a problem, as there is a tendency for the molten
metal to form a parabolic shape due to the competing gravitational and centrifugal forces.
Figure 6.1: Vertical Axis Centrifuge vs. Horizontal Axis Centrifuge (taken from
www.thelibraryofmanufacturing.com).
Figure 6.1 shows how the different axis techniques work. As you can see the vertical axis
centrifuge is being used for a part with low length-to-diameter ratio compared to the horizontal
7

8. axis, which is casting a pipe with a higher length-to-diameter ratio.
7. Design
7.1 Design Criteria
To begin with the design of the machine, we took the design criteria laid out by Dr.
Simionescu and used them as a springboard to a preliminary design. From here, we came up
with some essential elements that the machine will have to have in order to function. A list of
these elements are as follows:
Drum – this is essential to the casting capability of the machine. The drum couples the
casting mold to the rotating reference frame of the drive shaft in order to apply
centrifugal force to the molten metal.
Rotating Element – this is comprised of the drive shaft, bearings, coupling, and drum.
The rotating element (shaft and all rotating parts) must be capable of handling the torque
load of the motor, dynamic load of inertial bodies (including imbalance caused by
eccentricity of gravity centers and misalignment), and static load of components (drum,
mold, molten metal, shaft, and couplings).
Frame – in order to transfer torque, the motor body and drive shaft bearing outer races
must be held in a stationary reference frame. To do this, we will employ a rigid structure
that will support the static and dynamic load of the entire rotating element motor.
The criteria originally proposed by Dr. Simionescu were stated thus:
Vertical axis orientation
Electric motor drive
Capable of handling the maximum angular velocity of the motor (≈1800 rpm)
From this starting point, the team proposed the design in Figure 7.1. Dr. Simionescu's main
issue with this design was the height of the apparatus. While directly coupling the motor to the
drive shaft is practical for most general cases, the safety risks incurred from having to pour
molten metal at such a height eventually killed the idea.
8

9. Figure 7.1: A CAD sketch of the preliminary design.
Yet another problem with this design was the inefficient use of materials. Constructing the
device similarly to Figure 1 necessitates a longer shaft, a more robust and complex frame, and
a certain degree of alignment between the motor shaft and drive shaft, which can be hard to
accomplish.
These problems indicate the volatile nature of design criteria in the fledgling stages of
the project. Where the team tried to follow Dr. Simionescu's criteria precisely, the team failed in
adhering to safety standards and general regard for design simplicity.
7.2 Design Alternatives
In the search to find different ways of transferring torque to the drive shaft, the team entertained
several different options. Some of these are:
Gear Transmission – A gear transmission (or gear reducer) uses sets of dissimilarly
sized gears to convert input torque/speed to a different torque/speed. The initial fear of
coupling directly to the shaft was the torque required to start rotation. A gear
transmission can aid in lowering the required startup torque. The tradeoff here is lower
startup torque in exchange for lower top speed. However, a new unit is needed if a gear
ratio other than the rated ratio is to be achieved. Also, gear transmissions are expensive
and difficult to manufacture, assemble, and repair.
Belt Transmission – A belt transmission allows relative motion between the belt and the
sheave mounted on the shaft, which provides superior protection against shearing forces
incurred during the stopping of the machine. Also, belt drives are particularly efficient,
tolerant of misalignment, and cheap. However, the mechanism involved requires the
use of (2) V-belt sheaves which are locked to the shaft by QD (Quick Detach) Bushings.
In addition to the challenges presented in the transmission system, we found that a side-by-side
motor-to-drive shaft assembly orientation was a very commonly used method in most centrifugal
casting machines. This helps to greatly reduce the overall height of the machine, and it requires
a significantly less sophisticated frame in order to function. The low profile of this orientation
style is also more pleasing to the eye, and generally takes up less room.
7.3Final Design
Through conversations with Dr, Simionescu and our own research, the team formulated the
design shown in Figure 7.2. This design shows a side-by-side orientation of the motor and
rotating element, with a V-belt transmission.
9

10. Figure 7.2: a CAD sketch of the updated design with reference dimensions (inches).
Figure 7.3: A photo showing the bottom view of the final design.
The final design also features a few more essential elements, such as safety features and an
updated bearing arrangement. The bearing arrangement was difficult for several reasons:
Using standard anti-friction bearings requires manufacture of shaft and housing
tolerances of .0005". While this is easily attainable in a professional machine shop, the
team does not have the time to both design bearing housings and have them made at a
machine shop. To solve this problem, the team plans to use mounted bearings, which
are bolt-on assemblies that are sold ready to install.
Mounted bearings are expensive, and selection is slightly limited. Also, typical ball and
tapered roller bearings require very good alignment to within thousandths of an inch to
function optimally. Again, this is easily attainable in a professional machine shop, but
realistically, the team needs bearings that can handle some misalignment.
For the above reasons, the team decided to go with two spherical roller bearings. These are
capable of both radial and axial load, and can withstand significant misalignment.
For the part we wish to cast, we decided to use a pump diffuser ring out of a multistage
barrel pump. Market value for parts such as this is high, and proving the ability to make them
cheaply shows a major motivation for parts manufacturers to look more closely into this
technology. In Figures7.3 and 7.4, we see the pump diffuser in question.
10

11. Figure 7.4: A photo showing the shape and size of the pump diffuser ring (inches).
Figure 7.5: A photo showing the profile of the pump diffuser ring.
To make the mold model, we first made 3D model of the part itself, which we will then use to
make a plastic mold of the part. We will then use the plastic die to pour wax and make a wax
positive of the part. The plastic mold will be made with a 3D printer, in four sections, then
joined. In Figures 6, 7, and 8, we see 3D models of the positive and cavity mold, along with a
draft angle analysis done in Solid Works.
For the sprue and runners of the mold, we will use wax rods and other preformed
shapes to attach to the positive using localized heating. Once the wax positive of the mold
cavity is completely constructed, the entire wax structure will be coated in layers of liquid
zirconia refractory coating and silica granules. This will then be baked, melting the wax and
creating a rigid casting mold, ready for molten metal. The mold will then be placed in the
casting mold chamber, held in place with loose sand, and rotated at 1200 rpm. While turning,
the molten metal will be poured, creating the part. After the part has been created, the finished
product will be checked for dimensional accuracy, surface finish, and casting quality.
11

12. Figure 7.6: A 3D model of the pump diffuser ring.
Figure 7.7: A draft angle analysis of the diffuser ring for mold making.
Figure 7.8: A 3D model of the mold cavity for the diffuser ring.
12

13. 8. Feasibility Analysis and Project Justification
8.1 Economic
The effect on the economy in the past has been positive in advancing and improving
different types of centrifugal casting machines being developed. Today there are many
advanced centrifugal machines that have been designed to manufacture at a low cost while
producing a high quality product. Casting processes have been developed over the years by
application, material, and economics. These casting machines are in great demand in the
market today. The overall effect on the economy will be large. Creating a product like the one
described could potentially be an enormous factor for businesses that haven’t yet figured out
how to procure higher profile work by industrial businesses, such as refineries, chemical plants,
equipment repair shops, and other businesses. The cost of the project has been estimated at
around 1000 – 1500 USD. In Figure 1 shown below, a basic parts list and budget can be found
neglecting man hours to build the machine. Amounts are approximate, and better estimations of
price will come as design elements are formally decided upon. Upon further inspection, it will
become evident that the bearings are expected to be the most expensive element of the
machine. The team has chosen to use flange-mount bearings, which come complete and are
the easiest to used and design for. They are expensive because of their ruggedness and
convenience. Conventional anti-friction bearings require special design allowances and
provisions, which would likely end up being more costly due to increases in man hours needed.
Table8.1: Parts list and budget
8.2 Environmental
Environmental issues in the past have polluted the environment with emission of harmful
and poisonous gases, dust, and particles. Also, in the past the use of sand in casting moulds is
typically not recycled. Another environmental issue is the use of water as a coolant, which can
become contaminated and run off into local waterways. Today, companies and entrepreneurs
are designing and developing new systems capable of real energy saving. The vertical
centrifugal casting is a machine that will run off of a 3 AC induction Motor that will be controlled
by a control inverter which in turn controls the speed according to the actual requirements of the
product cycle running at that certain time. Therefore, in this way, the machine will be used only
when the required resources are available which will prevent energy from being wasted. To
13

14. prevent environmental issues, the team will fight pollution by controlling the emissions, proper
recycling, and waste disposal of the additional material.
8.3 Sustainability
The market is in high demand and casting machinery parts is steadily improving. Value
for the customer is created by the special nature of what this device is able to achieve. Future
markets are worried about producing a high value part at a cheap price. This product can meet
those requirements in market demand.
8.4 Manufacturability
Materials that can be used with this process are iron, steel, and alloys of copper and
aluminum. Material availability should not be an issue. The client will now have the opportunity
to purchase custom components whereas the OEM used to be the only place the client could
find particular parts for the company’s machine. In centrifugal casting, complexity can be
achieved, but with fewer defects, significantly better material properties, and near-net shape.
The combination of better quality and less waste mean that the profit potential for such a device
is high. Whereas a conventional casting operation must use a large portion of its capital on
overhead costs due to scrapped parts and extra labor, compared to a small scale centrifugal
casting outfit can produce small runs of complex, hard-to-make parts. By doing this, the
business can afford to sell these parts at large margins while still undercutting the OEM’s prices.
8.5 Technical
Risk factors are important when designing and building the vertical axis centrifuge. The
drum design revisions are needed to eliminate any hot molten metal being disbursed during the
process. Building a drum and testing it out apart from the rest of the machine can easily abate
the risk. This is a simple process that can save a lot of time down the road. Pouring the mold is
more difficult than expected. Pouring the mold can nearly be impossible to detect until it comes
time to pour metal. Some risk will have to be accepted here. Overall there are some risk factors
to take into account, but following technical guidelines and safety matters will eliminate risk
8.6 Ethical
There should be no injury or harm to the society. The machine design is small and all
casting processes will be conducted in a safe environment. Uses that could be an issue to the
society could be a facility with an assembly of machines that produce a lot of heat and noise
from casting. Whereas this is one machine that is small and there shouldn’t be much heat
generated as well as noise. An ethical issue someone might encounter while working on this
machine is seeing another team member or employee being dangerous with machine, or not
properly disposing waste.
8.7 Social
Society might misjudge the casting machine as a dirty, noisy, hot, and heavy industry.
This may lead to complaints from the community. All employers and clients will be treated
equally from discrimination based upon those employees, and client’s race, color, religion, sex,
or national origin.
8.8 Health and Safety
Safety and health, is very important in the casting industry due to the hot molten metal
being poured, toxins off of the molten metal, and the drum being spun at such high revolutions
per min. The injury rates for casting are higher than those of other private industries. Molten
metal is handled around 1200- 1450 degrees Fahrenheit to avoid solidification. Handling the
molten metal is extremely dangerous, if the molten metal comes in contact with the human body
14

15. it can cause serious burns, and damage to the human body. When dealing with molten metal
the person working with it should always wear protective clothing such as safety glasses, hood if
needed, face protection, ear plugs, thick welding gloves, and protective clothing. Handling of hot
materials requires special training, and monitoring.
8.9 Political
Political issues with vertical centrifugal casting machines are competition of other
companies, cost of capital, and the taxes. Designing and developing the casting machine will
result in competition with current and future developing companies. The competition can easily
reduce the cost of the product, and the labor. The cost of the high quality product and the cost
of distributing the product due to weight to different locations such as different states, and
oversees can be costly resulting in political issues.
9. Project Plan
The projectplan the team is proposing will be laid out completely in this section. The
action plan, WBS, RACI matrix, AON diagram, Gantt chart, timeline, resource
allocation/leveling, evaluation plan, risk analysis, and business plan will all be found in this
section.
9.1 Action Plan
The project is broken up into several phases, all which culminate in a defining milestone
that marks the completion of each phase. The action plan phasing scheme works as follows:
Planning Phase – the planning phase is comprised completely of tasks related to early
planning of the project (research, funds procurement, etc.). We considered this process
apart from the design phase because it only includes non-essential exploratory tasks
that are incident to the actual design of the device.
Design Phase – the design is comprised of tasks related to the design of the device,
including calculations, drawings, targeted research, and parts lookup.
Assembly/Manufacturing Phase – the assembly phase includes the purchasing and
manufacture of parts and all tasks related to the building of the device and the
manufacture of the casting mold. In this phase, design changes should be have very
low impact and should also be extremely infrequent.
Testing Phase – the testing phase only includes related to running the machine and
making parts for evaluation. This phase contains the evaluation of final castings for
quality and finish. The end of this phase will also be the end of the project.
The action plan itself contains all of the tasks in the project, their duration, their
predecessors, and who the task is assigned to. As far as the division of work, the team tried
to allocate tasks according to each member's individual strength and interest. However, the
changing nature of the project sometimes makes it necessary to switch the task assignment.
When this happens, the Gantt chart is updated and the linear responsibility chart is changed
in kind. A few changes have been made since the previous implementation of the Gantt
chart. We have tried to reduce the number of tasks by integrating several similar or
repetitive tasks into a single task. This has done a great deal to reduce the complexity of
our project and make the critical path a bit clearer. Before, many low level tasks were called
out that were difficult to track, as they were part of larger, more definable tasks. Since
making the change, the project has new energy and a much more defined direction. As we
are nearing the end of the first two phases, we find that scope creep has been a little bit of
an issue, as our sponsor, Dr. Simionescu has found a few of our design elements to be
questionable. We have been in a bit of a scramble to fix these issues before the conclusion
of the semester, so that we can be ready to build by the time Spring 2014 semester begins.
Please see Table 9.1 below for the vertical axis centrifuge action plan
15

16. Table 9.1: A table showing the action plan for the project.
ACTION PLAN
Task Number
Task Name
Duration
1
Planning Phase
15 days
Predecessors
Resource Names
15 days
2SS
SUMMARY
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Derek Veuleman
2
Literature Review
15 days
3
Procurement of Funds
4
5
6
Preliminary Calculations
Planning Complete
Design Phase
15 days
0 days
26 days
3SS
7
Finalize Concept
1 day
8
Design Rotating Element
2 days
7
9
Design Belt Transmission
2 days
8
1
Shehryar Niazi
MILESTONE
SUMMARY
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Derek Veuleman,Samir
Abusetta
Derek Veuleman
10
Design Motor Fixture
2 days
11
Design Mold Fixture
2 days
8SS
Michael Frazier,Shumeng
Wang
Derek Veuleman
12
Create Detail Drawings of Parts
5 days
8,11,10,9
Derek Veuleman
13
Final Performance Calculations
4 days
12
14
Build Bill of Materials
4 days
15
Design Complete
8SS
0 days
16
17
Manufacture & Assembly Phase
Centrifuge
33 days
12
6
33 days
Plasma Cut C.S. Plate Parts
5 days
19
Order Needed Parts and Material
10 days
18SS
20
Mfg. Shaft, and Bearing Mount
10 days
18SS
21
Weld Structural Parts
5 days
18
22
Assemble Centrifuge
10 days
18,19,20,21
23
24
25
Add Safety Features
Mold
Create 3D Die Model
5 days
33 days
5 days
22
26
Mfg. Die
15 days
25
27
Mfg. Wax Positive
5 days
26
28
Coat With Refractory Material
8 days
27
29
30
Assembly Complete
Testing Phase
0 days
33 days
22,28
16
31
Dry Run
10 days
29
32
Cast First Part
5 days
31
33
Make Improvements
5 days
31
34
Cast Final Part
2 days
33
35
Evaluate Project Success/Prepare
Report
12 days
34
0 days
35
Project Complete
16
SUMMARY
SUMMARY
Michael Frazier,Shumeng
Wang
18
36
Shehryar Niazi
Derek Veuleman,Samir
Abusetta
MILESTONE
Shehryar Niazi,Derek
Veuleman
Derek Veuleman
Samir Abusetta,Shumeng
Wang
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Samir Abusetta
Derek Veuleman
Shehryar Niazi,Shumeng
Wang
Derek Veuleman
Derek Veuleman,Samir
Abusetta
MILESTONE
SUMMARY
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Michael Frazier,Derek
Veuleman,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
Derek Veuleman,Michael
Frazier,Samir
Abusetta,Shehryar
Niazi,Shumeng Wang
MILESTONE

17. 9.2 Work Breakdown Structure and Linear Responsibility Chart
The work breakdown structure is very similar to the action plan. The main difference is
the fact that is shows who is responsible for the task, as well as the duration and precedence of
each task. The WBS is difficult to formulate, as it takes on myriad forms depending on the
project and group in which it is conceived. In our case, the WBS is just a simplified form of the
project plan, showing basic predecessors and the party ultimately responsible for the step. The
WBS can be seen below in Table 9.2:
Table 9.2: A table showing the work breakdown structure for the project.
WORK BREAKDOWN STRUCTURE
Steps
1. Planning Phase
a. Literature Review
b. Procurement of Funds
c. Preliminary Calculations
2. Design Phase
a. Finalize Concept
b. Design Rotating Element
c. Design Belt Transmission
d. Design Motor Fixture
e. Design Mold Fixture
f. Create Detail Drawings of Parts
g. Final Performance Calculations
h. Build Bill of Materials
3. Manufacture & Assembly Phase
3.1 Centrifuge
a. Plasma Cut C.S. Plate Parts
b. Order Needed Parts and Material
c. Mfg. Shaft, and Bearing Mount
d. Weld Structural Parts
e. Assemble Centrifuge
f. Add Safety Features
3.2 Mold
a. Create 3D Die Model
b. Mfg. Die
c. Mfg. Wax Positive
d. Coat With Refractory Material
4. Testing Phase
a. Dry Run
b. Cast First Part
c. Make Improvements
d. Cast Final Part
e. Evaluate Project Success/Prepare Report
Duration
15 days
15 days
15 days
15 days
26 days
1 day
2 days
2 days
2 days
2 days
5 days
4 days
4 days
33 days
33 days
5 days
10 days
10 days
5 days
10 days
5 days
33 days
5 days
15 days
5 days
8 days
33 days
10 days
5 days
5 days
2 days
12 days
17
Predecessors
1.a
1.b
1
2.a
2.b
2.b
2.b
2.b,2.c,2.d,2.e
2.f
2.f
2.f
2.h
2.h
3.a
3.1.a,3.1.b,3.1.
c,3.1.d
3.1.e
Responsibility
SUMMARY
Team
Derek Veuleman
Shehryar Niazi
Team
Derek Veuleman
Derek Veuleman
Samir Abusetta
Michael Frazier
Derek Veuleman
Shehryar Niazi
Team
Derek Veuleman
Shumeng Wang
Derek Veuleman
Derek Veuleman
Team
Shumeng Wang
3.2.a
3.2.b
3.2.c
Shumeng Wang
Shumeng Wang
Derek Veuleman
Team
3.1, 3.2
3.1,3.2
4.b
4.c
Team
Team
Team
Team
4.d
Team

18. The linear responsibility chart, or in our case, RACI matrix, is an extremely useful tool for
establishing a "pecking" order, so to speak, for the project tasks. Many times, in large projects,
it becomes important to track accountability for particular tasks. Due to the fact that team
members in any given project will not have the exact same skill set, experts must be held
accountable for the success or failure for particular tasks which they are especially suited to
handle. Many times, the accountability still lies with the project manager, but responsibility of
the task sits with the person actually performing the task. These complexities associated with
the organizational structure of the project team are more easily seen in a RACI matrix, which is
why they are often used to direct the flow of communication through the project team. In the
case of our team, Derek Veuleman and Samir Abusetta have skills particularly suited to rotating
equipment, so they are ultimately responsible for the design. Also, when the project plan is split
into work packages, it becomes very clear where accountability and responsibility lie, and who
should be contacted in case of an issue. The RACI matrix for our project is shown below in
Table 9.3. Be advised that the RACI matrix makes specific reference to the WBS (Table 9.2).
Table 9.3: A RACI matrix to complement the WBS table.
1.a
A
R
I
C
1.b
I
C
I
R,A
1.c
I
I
R,A
C
2.a
R
I
C
A
2.b
R
C
C
R,A
2.c
R
C
C
R,A
2.d
A
I
I
R
2. Design Phase
2.e
R
C
C
A
2.f
C
C
I
R,A
2.g
I
I
R
A
2.h
R
C
C
A
3.1.a
R
C
C
A
3.1.b
R
C
C
A
3.1.c
C
C
C
R,A
3.1 Centrifuge
3.1.d
C
C
C
R,A
3.1.e
R
R
R
A
3. Manufacture &
Assembly Phase
3.1.f
R,A
I
I
C
3.2.a
I
R
I
A
3.2.b
C
R
I
A
3.2 Mold
3.2.c
C
R
C
A
3.2.d
C
R
C
A
4.a
R
R
R
A
4.b
R
R
R
A
4. Testing Phase
4.c
R
R
R
A
4.d
R
R
R
A
4.e
R
R
R
A
Legend:R = Responsible | A = Accountable | C = Consult | I = Inform
1. Planning Phase
18
Shumeng
Wang
Derek
Veuleman
Shehryar
Niazi
WBS
Michael
Frazier
Samir
Abusetta
RACI Matrix
I
I
I
I
C
C
I
C
I
I
C
C
C
C
C
R
I
R
R
R
R
R
R
R
R
R

19. 9.3 Network Diagram
The network diagram (in this case, an activity-on-node diagram) serves a particular
purpose within the toolbox of the project manager. In the case of our project the network
diagram was extremely useful in identifying our critical path. In Figure 9.1 below, an AON
diagram of the summary tasks of our project is found (please reference Table 9.1 above for task
ID numbers). The way that our project is currently set up, all summary tasks are currently on
the critical path. This is mostly due to the fact that we have some hard deadlines set for
completion of each phase. Several of these are externally set by our professor, Dr. Ruby, and
some are artificially imposed by the team. However, many of the tasks within each phase are
not critical. The slack time of individual tasks and the slack in summary tasks do not comport
because of the links between tasks. Many of our tasks are start-to-start because their parallel
operation makes for the most effective use of time. By taking the time to carefully link tasks in
the beginning, we have avoided some of the pitfalls associated with resource allocation later on
down the road. Allocation problems will be addressed in section 9.5.
Figure 9.1: An AON diagram for summary tasks only (complete AON can be found in
appendix).
19

20. 9.4 Timeline
The project timeline is greatly influenced by the university semester schedule. As a
result of the project being split into two large pieces, Fall 2013 and Spring 2014, it has become
of paramount importance that the project has continuity between the two semesters.
Information that is incomplete or tasks that are unfinished become very difficult to manage after
a long expanse of time has elapsed. We have decided as a team to finish the design and get a
head start on construction before the end of the semester. This is difficult when done on limited
time, but it will help us greatly in the future to avoid some slippage in the last round of tasks.
Figure 9.2: A Gantt chart diagram showing the current phase tasks and all summary
tasks (full Gantt chart can be found in the appendix).
Upon inspection, it becomes evident that each task is given ample "play" for the purposes of
contingency allowance. This is more evident on the AON diagram in the appendix. Rather than
specifically plan for contingency, the team decided to add a margin of contingency to each
individual task that adds up to a large allowance. This way, the project schedule always
appears to be on time in the case of moderate slippage. Also, this contingency time can be
used conveniently to crash the project.
This project is unique in that we have an unavoidable deadline at the end of the project:
April 30, 2014. As the team will be graduating soon after, this deadline simply cannot be
pushed out. This results in more tasks being critical, and means that slack must be made up
for by the end of the project. This presents an interesting challenge which I present our solution
for earlier.
9.5 Resource Allocation
Resource allocation in this project has proved to be an exceptionally daunting task. We
learned early on that attempting to accurately track man hours without a formal system was a
fool's errand. For this reason, we decided to assign tasks as if everyone were working full time.
The only real control we have here is that tasks are assigned to specific team members. The
actual amount of time spend per task becomes irrelevant to our project, as we do not receive a
wage for our labors. However, the project schedule is still followed, as each finish date serves
as a deadline.
Resource loading in our case is fairly straightforward. All design oriented tasks are back
loaded, as these are the hardest to get rolling. Many times, the bulk of the work is sent simply
understanding problem before getting involved in the theory. Currently, construction task are
loaded toward the middle of the duration, as the beginning of these tasks are mostly spent in
20

21. preparation (getting tools ready, preparing parts, preparing the work area). This may change as
we progress, but we believe this to be a fairly true-to-life assessment.
Resource leveling in our project was difficult to perform. Attempting to automate the
process in Microsoft Project was disastrous, as nearly attempt at auto-leveling seemed to
drastically change the project plan. For this reason, most of the leveling was done manually, in
specific spots that were having allocation problems. For tasks that required the entire team,
such as construction and testing, the work unit for each resource were changed to
accommodate the overload of hours.
9.6 Testing and Evaluation Plan
We are very fortunate in that our project's deliverables are exceptionally easy to test and
validate. In the case of the centrifuge itself, its operation can be easily tested to validate that it
is up-to-spec and functioning properly. The plan for this is as follows:
Positive Material Identification – an XRF (X-ray fluorescence) analyzer to get the exact
chemical makeup of the final cast material.
Surface Finish Comparator Test – the surface finish of the casted part will be tested to
find the precise finish characterization.
RPM verification – the rotational speed of the device will be confirmed by the use of a
handheld tachometer.
Vibration Analysis – the vibration characteristics of the device will be tested by a
handheld device specifically designed to test for the vibration characteristics of rotating
equipment bearings.
After obtaining this data, it will be compared against known standards (see section 13) and
checked for deviation. The project plan itself will be evaluated by deviation from budget,
schedule slippage, and the amount of corrections that must be made in the final phase of the
project. If the project is finished within budget, within scope, and on time, we will not hesitate to
call the project a success. However particular attention will be paid to slippages, as these have
to be made up later in the project in the form of taking slack away from other tasks further along
in the project. This can force previously non-critical tasks into the critical path if their slack time
is used for slippage correction.
9.7 Risk Management Plan
In the team's risk management plan, all but one step of the risk management process
have been implemented. In Tables 9.4, 9.5, and 9.6, qualitative analysis, quantitative analysis,
and risk response planning tables can be found. These all imply that risks have been identified.
As we move forward with the project plan, potential pitfalls are monitored, and an eye to the
future is always cast with the intention of catching potential problems in their infancy, rather than
wait for them to fully materialize into big issues. Tools such as those presented in the follow
tables help the project manager to assess the current risk profile and apply remedies based on
a predetermined set of criteria, in this case, the risk response planning table. This table states
all of the known risks and offers a response plan for each. This is an invaluable tool for teams
to invest in, and with complete input from team members, it can insure that all members know
what is expected when problems arise.
For the monitoring and control parts of the process, we are currently working on a
scheme under which we can all operate that will take risks into account. We are currently in the
design phase, which has the fewest risks attached to it. Since we know that the manufacturing
phase will be the riskiest part of the project, we are trying to get a good risk management and
control system going to prepare. A large part of this will be implementing step number 7 of the
process, which calls for the use of a permanent register to keep all of the risk identification and
planning response information in a central location.
21

22. Table 9.4: A qualitative risk analysis table.
Risk Matrix - Vertical Axis Centrifuge
1. Casting mold difficult to
manufacture/procure.
2. Pouring the mold is
more difficult than
expected.
1. Drum design revisions
needed.
High
1. Tight scheduling
pushes deadlines out.
Medium
1. Budget overruns by
<20%
1. Imbalance cannot be
mitigated using
conventional methods.
Low
1. Bill of Materials is
incomplete; expedited
order of minor
consumables needed.
1. Budget overruns by
>20%
1. Safety concerns
prohibit testing.
Low
Probability
1. Needed parts have long
lead times.
2. Manufactured parts
are out of spec/unusable
due to dimensional
defects.
Medium
High
Impact
Table 9.5: A quantitative risk analysis table.
Failure Mode and Effect Analysis (FMEA)
THREAT
SEVERITY, S
LIKELIHOOD, L
ABILITY TO
DETECT, D
RPN
9
7.5
6.5
3
8
7
5
8.5
8.5
5.5
8
8
4
7.5
6
3
8
6
4
8
5
3
5
4
612
247.5
208
192
160
157.5
150
102
8
4.5
2
72
7
2
4.5
2
2
4
63
16
Tight scheduling pushes deadlines out
Needed parts have long lead times
Casting mold difficult to manufacture/procure
Drum design revisions needed
Budget overruns by >20%
Pouring the mold is more difficult than expected
Budget overruns by <20%
Safety concerns prohibit testing
Manufactured parts are out of spec/unusable due to dimensional
defects.
Imbalance cannot be mitigated using conventional methods
Expedited order of minor consumables needed
22

23. Table 9.6: A risk response planning table
Risk Response Planning
THREAT
RISK RESPONSE
PLANNING
APPROACH
Tight scheduling pushes deadlines out
Mitigate
Needed parts have long lead times
Casting mold difficult to manufacture/procure
Avoid
Mitigate/Accept
Drum design revisions needed
Mitigate
Budget overruns by >20%
Mitigate
Pouring the mold is more difficult than expected
Mitigate/Accept
Budget overruns by <20%
Mitigate
Safety concerns prohibit testing
Mitigate
Manufactured parts are out of spec/unusable due to
dimensional defects.
Accept
Imbalance cannot be mitigated using conventional methods
Expedited order of minor consumables needed
Mitigate
Mitigate/Accept
23
REMEDY
This risk can be mitigated by careful planning
and high productivity. If the project begins to
slip on deadlines early on, the problem is likely
to get worse.
The idea here is to avoid this risk by finalizing
the design on time and ordering parts early, so
that plenty of time is allowed for shipping.
This is a high priority risk that will be difficult
to mitigate. We will try early on to procure a
mold to avoid manufacturing our own, but on
some level, we must accept that this will likely
be a major challenge.
This risk can be easily abated by building the
drum and testing it out apart from the rest of
the machine. This will be a simple process
that can save a lot of time down the road.
For this risk, a detailed and accurate estimate
of price will be essential. To maximize
mitigation, it is imperative that the estimate is
done at the end of the design phase.
This risk will be nearly impossible to detect
until it comes time to pour metal. A dry run
will help a little with this risk, but even this will
require the assembled machine. Some risk
will have to be accepted here.
For this risk, a detailed and accurate estimate
of price will be essential. To maximize
mitigation, it is imperative that the estimate is
done at the end of the design phase.
This risk can easily be mitigated by the
addition of safety features and procedures
that are aligned with OSHA standards.
Unfortunately, it is nearly impossible to detect
a manufacturing defect until it is too late. This
risk will have to be accepted or worked
around.
If, during initial tests, we detect excessive
vibration levels, there are a number of
unconventional methods that can be applied
on the fly (field balancing) in order to balance
the machine and have it function safely.
Research on the application of these methods
will be necessary.
We will try very hard to anticipate all needs
ahead of time, but there is always a chance
we might miss something. We will mitigate
risk by making the Bill of Materials as
complete as possible, but we will have to
accept, to some degree, that we may miss
something minor.

24. 9.8 Business Plan
9.8.1 The Market Idea
In the time since North and Hall succeeded in producing interchangeable parts in
the early 18th century, much has been done in industry to make sure that the equipment that
keeps businesses working is productive and reliable. However, as the industrial revolution
burgeoned a new level of reliability, machinery began to last ever longer. The result is a large
number of industrial machines that have long outlived their own obsolescence, product line, and
in some cases, even the manufacturer itself. This leaves end-users in the precarious position of
facing either astronomical redesign and replacement costs, or the logistical nightmare of reverse
engineering an obsolete machine. Unfortunately, many who lack the knowledge or gumption to
face the challenge of reverse engineering end up simply paying a company to handle the
problem. In the process, a great deal of time and money are squandered on what is, ostensibly,
an easy way out.
9.8.2The Product Idea
The problem described above is a common side effect of the ever-aging
infrastructure of our refineries, power plants, chemical manufacturing facilities, and city utilities.
The proposed solution is a device which is capable of using a centrifugal casting process to
make parts. Whereas many of the parts inside of any given machine are made by conventional
machining methods, a few of the more complex parts require a process that is capable of more
intricate details. With conventional casting, complex shapes can be achieved by using a
shaped mold. In centrifugal casting, the same level of complexity can be achieved, but with
fewer defects, significantly better material properties, and near-net shape. The combination of
better quality and less waste mean that the profit potential for such a device is high. Whereas a
conventional casting operation must use a large portion of its capital on overhead costs due to
scrapped parts and extra labor, a small scale centrifugal casting outfit can produce small runs of
complex, hard-to-make parts. By doing this, the business can afford to sell these parts at large
margins while still undercutting the OEM's prices. The device in question will be capable of this
level of quality, as well as being reliable and easy to use.
9.8.3The Market Served
The idea here is to use the device to complement the services that industrial
equipment manufacturers and equipment repair centers already provide to their customer base.
These businesses will already have a great deal of the infrastructure in place needed to sustain
a casting operation, such as machining and drafting capabilities, as well as safety procedures
and zoned industrial facilities. Companies looking to expand the scope of what they're able to
offer their customers will take great interest in the capabilities of this product.
9.8.4The Customer Value
Value for the customer is created by the special nature of what this device is able
to achieve. Purchasing spare parts from an OEM often results in inflated prices and long lead
times. The reason for this is that many times, end-users have no one else to turn to. When a
critical piece of equipment breaks down, sometimes the only party capable of producing a fix is
the OEM. With the proposed product, the hope is that third party shops become empowered to
contest the OEM's market share and ultimately provide the customer with higher quality
products and faster turnarounds.
9.8.5Revenue Generation
Revenue will initially be generated by limited retail sales to area businesses in
order to study the market impact and gauge customer interest. Once these variables have been
24

25. set, attempts will be made to license the idea to an existing manufacturer. Since an established
manufacturer will already have many important relationships with clients, it would be wise to
assimilate this product into their already existing market share, rather than try to carve out a
niche independently. After these deals are set, revenue will be generated in the form of
licensing fees collected from a participating corporation.
9.8.6Economic Impact for the Coastal Bend
Impact for the Coastal Bend will be large. As a result of the fact that the Coastal
Bend is beset on all sides by industrial businesses, such as refineries, chemical plants,
equipment repair shops, etc., a product like the one described could potentially be a gamechanger for businesses that haven't yet figured out how to procure higher profile work. Also,
this product encourages competition between OEMs and aftermarket parts manufacturers.
Whereas the OEM used to be the only place you could find particular parts for your machine,
now, many facilities will be capable of this type of manufacturing. The resulting competition
results in a buyer's market, which creates added value for the customer. Hopefully, this
competition will raise local standards regarding manufacturing ability and quality, as well as
create jobs for residents by giving locals businesses a new venture to look into.
10. Cost Analysis and Justification
10.1 Cost of Building
In depth cost analysis is shown in Table 9.7: Bill of Materials. The prices varied at
different online stores. The table includes the highest possible prices and the lowest possible
prices that give us a good idea of what our expense range is going to be. The highest possible
total turned out to be $1545 and the lowest possible total is $860. Till next semester we’ll still try
to find cheaper materials if possible that could sustain the same workload.
Table 10.1: Bill of materials
BILL OF MATERIALS
VERTICAL AXIS CENTRIFUGE
MATERIAL
QTY.
Baseplate
Angle Plate
Drum
Turntable
Coupling Sleeve
Drive Shaft
Thrust Bearing
Radial Bearing
V-Belt Sheaves
QD Bushings
V-Belt
Keys
Consumables
1/8" C.S. Plate
3/8" C.S. Plate
1/8" C.S. Tubing
1/4" C.S. Plate
1/8" C.S. Tubing
1018 Cold Rolled Steel
Various
Various
Cast Iron
Cast Iron
Rubber
Carbon Steel
Various
1
1
1
1
1
1
1
1
2
2
1
3
N/A
TOTALS
25
HIGH
Price
50
75
100
50
20
100
400
400
60
60
50
20
50
LOW
Price
35
50
75
35
10
75
200
200
30
30
30
10
20
1545
DESCRIPTION
860

26. 10.2 Justification
The casting machine that we’re making will prove to be great value. Individuals and
businesses pay a huge amount to get a custom part casted. Using this machine we’ll be able to
earn our investment back by making just two to three parts. Even if we have to use to for a small
business we could make parts with it that would otherwise cost thousands of dollars.
11. Implementation Plan
We plan on starting to build the prototype as soon as the Spring 2014 semester starts. The
parts that we have to order are:
Pipe for mold chamber
Shafting material (1018 Cold Rolled Steel)
¼" Carbon Steel Plate (for the majority of the structure of the machine)
Structural C Channel for the siderails of the skid
1½" Angle Iron for supports
Mounted Bearings
Hardware (nuts, bolts etc.)
Consumables (lubricant, solvent, paint etc.)
After all detail drawings have been made, and the plate has been received, all structural
components will be cut out with a CNC plasma cutter. After they are cut, they will be de-burred
and readied for welding. The skid, mold chamber, and motor stand will then be welded and
hand dressed to be ready for final assembly. Also, the drive shaft and accompanying sleeve will
be made in a lathe. After all structural components have been constructed, the machine will be
assembled, checked for function and painted.
We know exactly where to order the parts from and also know the materials that they are
going to be. The AC Motor is available in our school’s machine shop already and we will be
using that for our machine.
As soon as the parts arrive, which will not take more than 2 weeks; we will start assembling
them together. We’ve planned to completely assemble the prototype within a month and have it
ready for testing. The team will get busy with the other classes during the end of the semester,
which is why we plan on getting this done as soon as possible.We’ll keep testing the prototype
until we achieve the desired results.
12. Expected Results and Deliverables
The expected results and deliverables associated for this project will be as follows:
One (1) vertical axis centrifuge capable of accelerating a mass to 1200 rpm for the
purposes of centrifugal casting.
Centrifuge will be capable of safely rotating up to 200lbs. in weight.
One (1) casted part of either aluminum or bronze, with appropriate dimensional and
geometric accuracy.
One (1) set of mold dies for future production of parts, along with a detailed procedure
for the construction and preparation of the casting mold.
A set of instructions for use of the device, as well as safety documentation and warnings.
A complete parts breakdown of the device, populated with part numbers and
manufactures for future replacement and maintenance.
Surface finish of casted part will fall within machined surface criteria.
Casting will have very few inclusions and high alloy purity.
26

27. The above specifications were obtained using preliminary calculations and empirical data
received from various sources and first-hand accounts. Once the design is completed, this data
will be inspected for accuracy and cross-checked against manufacturing drawings and hard
calculations. The checks and calculations will become part of the documentation that is
provided to the customer upon the conclusion of the project. Details such as this are
considered essential communication to the client, and must be well developed and researched.
In the beginning, we will likely have some vibration and balance issues as a result of the
challenging nature of the problem. Once the issues have been worked out, we hope to provide
a product that operates within the customer's parameters and that continues to be reliable for a
long period of time.
Deliverables will be ready no later than April 30, 2014, and all pertinent documentation
will be handed over, along with the product itself at that time.
13. Evaluation Plan
Once we’ve assembled all the parts we’ll try different tests in order to check if everything
is working fine. First the motor will be switched on and we’ll let the drum spin without any metal
poured in. If the first test is passed we’ll try pouring in water at room temperature to check if
there is any leakage or splashing of the liquid. We’ll try this numerous times because if this test
fails it will mean that the super-heated molten metal will probably splash too which could be
fatal. Once both the tests are passed we’ll wear safety suits and will try doing the same process
but with molten metal this time. Once the metal has solidified we’ll check for any impurities and
will fix any issues that arise until the geometric flaws are almost negligible. We aim to make high
quality finished parts that are built to last for a long time and can be used as spare parts in very
reliable machinery.
Since we’re done with all the design and have picked the materials already, we’re ready
to order and assemble the parts and test the machine out.
14. Monitoring and Control Plan
The centrifugal castingmonitoring and control plan progress are to review content and
the quality of project deliverables, to ensure that project objectives are being met, performance,
and project cost, schedule, quality, risk, and scope are be controlled. While the project
continues to progress and to be terminated some changes had been required from time to time,
the changes kept tracking in timeline and budgetary considerations, the most tasks that were
monitored are design phase, the project deadline and the budget. Also keeping an eye on team
performance and reacting quickly and appropriately to any emergent issues to make positive
changes. As the project progresses through each phase the scope of the project maintained
well and documentation related to completed portions of the project are stored and organized
for future reference. The centrifugal casting project has a schedule baseline that Monitor the
project properly to decrease the chances of schedule issues that eventual becomes major
setback.
The cost of the project maintained to be a key factor for success without affecting the
cost of any task phase. Keeping track of any changes in budget will not affect directly because
our team has fixable resources that can be added to overall affected budget. Reporting quality
control issues were applied to support the accuracy and some adjustments made to insure the
quality of the outcome of our project.
To monitor performance of the project and its data is important to complete proper calculation to
timeline and phasing plans. Tracking risks might accrue in any phase plan of the project but our
team insures that the project will be completed in time with complete project specifications.
27

28. The budget and cost associated with centrifugal casting project is under control, our
team has flexible budget that can be added to the cost of terminating our project, the total
coasts of our project is $1450. The expect retail sale of this product and the licenses fee are
$3500 also the total items to be sold in the first yearly quarter are 6 item with total sales
$21,000. Earned Value Analysis can be seen in table 14.1.
Table 14.1: Earned Value Analysis
15. Audit Response and Termination Plan
The vertical axis centrifuge project needs to be closely monitored to prevent missing
deadlines, and to ensure the project is progressing. Sometimes problems occur during the
building of the project and become necessary to terminate the project before completion. Audit
response is a good way to identify problems earlier, clarify performance, reduce cost, speed of
achievement of results, provide information to the client, and many more to reduce the risk of
termination of the project. The team will review all elements of the project to identify the
strengths and weaknesses of the project.
The team's project auditor will be our faculty sponsor Dr. Simonescu who has
experience and expertise in vertical centrifugal casting. The project audit will examine
methodologies and procedures, properties, budgets and expenditures, degree of completion,
project management, and records. The results of the audit will be the progress of the ongoing
project and how to improve these recommendations. There will be ongoing audits throughout
the project (once every two weeks) to keep the project on track and to avoid termination. The
audit response will identify problems before they get out of hand, improve project performance,
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29. reduce cost, identify mistakes, remedy them, and avoid them in the future, and many more
results the auditor will suggest to the team. The main purpose of the audit will be to improve the
project and achieve the goals of the project.
16. Relevant Standards
Standards that need to be met by our Vertical Axis Centrifuge are listed below:
• ISO(International Standards Organization)
• 6178:1983 – Construction and Safety Standards for Centrifuges.
• OSHA(Occupational Safety and Health Administration)
• 29 CFR Part 1910, Subpart O – Machinery and Machine Guarding Safety
Standards.
• ASTM (American Society for Testing and Materials)
• B271 / B271M – 11e1 – Centrifugal Casting Standards for Copper-Based Alloys.
• B955 / B955M – 11 – Centrifugal Casting Standards for Aluminum-Based Alloys.
The above standards outline several functional and safety standards that need to be met by
the machine. These standards, particularly the ones that pertain to safety, will be incredibly
important to follow. The molten metal will be extremely hot, and the machine will be turning very
fast. Failure to meet basic safety codes could result in injuries and legal liability issues.
Machinery standards are slightly more lax, as our machine does not meet the size threshold for
ISO construction standards, we will still attempt to hold our machine to ISO standards, but it is
not as important as safety codes. ASTM codes give very detailed specifications on how
material should be treated, but unfortunately, the alloys we use will not be completely under our
control. We will try to follow them closely, but we acknowledge the reality of the situation.
17. Professional Goals and Necessary Skills
All the team members being mechanical engineering majors have similar professional
goals and skills. The team really wants to make this project a success. Adding this project to our
resume would make a really positive impact. The skills needed to generate a prototype design
required experience with AutoCAD. Despite all the team members knowing how to use
AutoCAD, Derek was the one who did the modeling as he was in charge of the design portion of
the project because he knew exactly how the casting machine should be. As mechanical
engineers, AutoCAD is the most commonly used software and gaining more experience with it
potentially makes our future career stronger. We also had to apply knowledge from strengths of
materials, dynamics, fluid mechanics, and mechanical system design classes in order to pick
the materials that we did.
18. Conclusions
The entire week-by-week schedule for next semester has been planned out and we’re
really looking forward to ordering the parts as soon as the classes start. Shehryar Niazi has
really good graphic designing skills and he’s planning to make flyers and an animated promo
video for the casting machine too. Derek and Samir still discuss about the design very often, as
they believe that a design can never be perfect and there is always room for improvement.
Shumeng and Michael discuss about the budget often always making sure that we don’t exceed
it. This semester has proved to be really productive for our team. We never thought we would
be able to come up with such promising design that would please our faculty mentor, Dr.
Simionescu, this much. The key was that the team mates had really good chemistry and did
take each other’s opinion seriously which eventually helped in making a solid design.
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30. References:
Wallace Henry W: Casting apparatus and method. / Moule et methode de coulee.American
Optical Corporation: US Patent1079021
Mirizzi, Michael S: Stent Made by Rotational Molding or Centrifugal Casting and Method for
Making the Same, United States Advanced Cardiovascular Systems, Inc. (Santa Clara, CA): US
Patent 6574851
Khandros, Igor Y: Centrifugal Casting, United States Abex Corporation (New York, NY) US
Patent 4357394
Spiewok, Leonhard (Wallisellen, CH), Bucher, Albert (Kriens, CH): Vertical centrifuge United
StatesEscher Wyss Limited (Zurich, CH) US Patent 4014497
Zhi Sun, et al: "Research of Mechanical Property Gradient Distribution of Al
Cu Alloy in Centrifugal Casting." Surface Review and Letters, Vol. 18, No. 6 (2011) 297 301.
World Scientific Publishing Company
Tsunashima, Kenji, Aoki, Seizo, Suzuki, Masaru: Casting Toray IND INC JP01241413
Manda, Jan Marius (Toronto, CA): Metal molding United States Husky Injection Molding
Systems Ltd. US Patent 20070181281
True Centrifugal Casting, www.thelibraryofmanufacturing.com
Material Properties, www.theengineeringtoolbox.com
Metal Prices, www.metalsdepot.com
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