Manufacturing of a Pump Body

Manufacturing of a Pump Body

Manufacturing engineering project conducted at Arts et Métiers (ENSAM), focused on the complete realization of a pump body — from casting to machining and dimensional control.

This project was part of a full-cycle manufacturing training program. The objective was to understand the complete industrial process behind the production of a functional part, through three key stages: foundry, machining (manual and CNC), and metrology. The final component had to meet tight dimensional tolerances and remain manufacturable under real industrial conditions.

Phase 1: Foundry

The casting mold was designed in sand, accounting for draft angles, joint planes, vents, shrinkage, and a machining allowance of about 3 mm. The chosen alloy was AlSi7, and molding was performed manually using clay-bound sand. This process ensured proper porosity and minimized alumina skin defects. The resulting casting showed realistic imperfections — such as surface granularity and minor mismatches — which were analyzed and documented as part of the study.

Phase 2: Machining

Machining was divided into two sub-phases:

• Phase 100: Manual turning — Facing and boring using a fixed-tool lathe. Performed at low speeds due to machine limitations, with noticeable tool wear caused by sand residues from casting.
• Phase 200: CNC turning — Tool path calibration via probing and CAD-based operation planning (faces C, D, and E). This stage offered higher precision and superior surface finish, suitable for small-series production.

Phase 3: Metrology

Dimensional inspection was carried out using a coordinate measuring machine (CMM) equipped with a 3-point electric contact probe. Measurements included flatness, perpendicularity, and cylindricity across multiple surfaces (E, C, and D). Gauss fitting and tolerance analysis confirmed proper alignment, but revealed slight non-compliance in cylindricity due to inherent casting limitations.

This hands-on project provided valuable experience with real-world manufacturing challenges: material selection, tool behavior, machine wear, tolerance validation, and quality control. It reinforced our understanding of industrial interdependencies and the balance between cost, precision, and performance in production engineering.

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