team tie-master brittany ballard cam leslie steve may

Team Tie-MasterBrittany Ballard

Cam LeslieSteve May

Tie-down Finishing MachineFinal Design

Project ProblemCurrent Situation: Surface of aluminum tracks

finished by-hand Burrs on edges from milling Chips from milling can get lodged in

the channel of the track Outer surface of the track is

inconsistent

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Project ProblemCurrent Issues: Manual surface finish is time consuming May pose health hazards

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Project Goal

Design, fabricate, and test a machine that

will automatically finish, de-burr, and clear

debris from several different tie-down track

profiles

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Specifications

Project Problem

Project Goal

Specifications

Conceptua

l Design

Detailed

Design

Manufacturing Processes

Final

Produc

t

Cost

Q & A

Conceptual Design

Broken into specific areas:

•Creating the Grain and De-burring •Removing Debris

•Track Movement

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed DesignCreating the Grain and De-burring

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed Design

Stresses were calculated w/ various increasing loads until failure predicted at 300 lbf.

FEA with ABAQUS

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed DesignRemoving Debris

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed DesignTrack Movement

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed DesignCATIA Model

This is the final design. The overall length is 4ft.

The case footprint is 14.5”x14”

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Detailed DesignCATIA Model

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Manufacturing Processes

Milling and welding were the two processes most used for this project

Many parts were ordered from manufacturers This will allow for easy replacement

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Final Product

Project Problem

Project Goal

Specifications

Conceptua

l Design

Detailed

Design

Manufacturing Processes

Final

Produc

t

Cost

Q & A

Final Product

Systems were tested separately Each system met specs when tested separately

Systems are currently being integrated

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Total Cost

Item CostTesting Materials $ 300Materials for Prototypes $ 100Materials for Final Product $ 1,500Machine Shop Infrastructure $1,000Travel Expenses $ 450Other Materials $ 150

Total cost ≈ $ 3,500

Initial Budget of $ 4,000

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Using the current setup, there are 2-6” pads and 4-5.6” pads in the finishing wheel stack

Cost of each pad is $2.58 ea The pad stack can be used for

approximately 200 ft of track, depending on the length of individual tracks

Media cost = $15.48 for 200 ft of track = $0.08 per ft of track

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Media Cost

Working HoursWork Description DurationConceptual and Detailed Design 432 HrsTesting 75 HrsMachine Shop (Fabrication) 375 HrsComputer-Aided Design 30 HrsPaperwork 60 HrsTOTAL 972 Hrs

• These hours include time for all group members (3)

• This equates to approximately 15.5 hrs of work per week, per person on this project

Future Adaptations

Kaizen Projects Make finishing pads last longer Layout of Mac’s shop

Other Features Adding a debris separator to funnel Future use on other aluminum parts Change placement of finishing pads for improved

grain

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A

Questions?

Project Problem

Project Goal Specifications Conceptual

DesignDetailed Design

Manufacturing Processes

Final Product Cost Future

Adaptations Q & A