team tie-master brittany ballard cam leslie steve may
DESCRIPTION
Final Design. Tie-down Finishing Machine. Team Tie-Master Brittany Ballard Cam Leslie Steve May. Project Problem. Current 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 - PowerPoint PPT PresentationTRANSCRIPT
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