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Paddle Maker Design and Material Optimization

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1. Several comments can be stated as well in relation to the material study Although the results were not as predicted the test gave us in depth understanding of the behavior of polymers and their wear properties The ball on disk is a test widely used for metal and ceramics In this case of testing the UHMW PE several phenomena like melting and plastic deformation seems to affect the wear volume which explains why the results are not as expected knowing tensile strength property There is a need to confirm the results through other test method such as hardness and pin on disk abrasive type In addition more statistical data is required A further search for better wear resistant materials such as study effect of radiation doses on the wear property should be followed As a group of prospective engineers extraordinary effort was taken by all members of the team to finalize the design and construction of a functional machine within the time limit presented in the Timeline chart as well as to find a material with better performance than the existing one 101 Paddle Maker Machine and Material Selection 10 Future Work Even though the prototype has already been finished and it is working some parts can be replaced to improve the overall efficiency quality and performance of the machine The two whole thread rods moving the drill and saw assembly should be replaced with lead screws Appendix P to improved accuracy production time an
2. FLORIDA INTERNATIONAL UNIVERSITY EML 4905 Senior Design Project A SENIOR DESIGN PROJECT PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING Paddle Maker Design and Material Selection Final Report Nestor Vega Jorge Ramon Orena Danoa Advisor Dr Sabri Tosunoglu This report is written in partial fulfillment of the requirements in EML 4905 The contents represent the opinion of the authors and not the department of Mechanical and Materials Engineering Paddle Maker Machine and Material Selection Ethics Statement and Signatures The work submitted in this project is solely prepared by the team consisting of Nestor Vega Jorge Ramon and Orena Danoa and it is original Excerpts from others work have been clearly identified their work acknowledged within the text and listed in the list of references AII of the engineering drawings computer programs formulations design work prototype development and testing reported in this document are also original and prepared by the same team of students Nestor Vega Jorge Ramon Orena Danoa Team Leader Team Member Team Member Dr Sabri Tosunoglu Faculty Advisor Paddle Maker Machine and Material Selection Acknowledgments The members of our team would like to thanks the following advisors and persons for their support and guidance during the last five month 1 Advisor Dr Tosunoglu Ph D U
3. X 5 68 sec Figure 49 Travel Time Using Precision Lead Screw 94 Paddle Maker Machine and Material Selection 8 Design Considerations 8 1 Assembly and Disassembly In every mechanical system where wear and tear exists the design challenge brings the concern of flexible and fast maintenance It is a fact that at some point in the life cycle of any machine maintenance will have to be performed to its moving components consequently the gaining easy access to these components that require maintenance is a characteristic that concerns every user Easy access means less time spent maintenance is done to the machine therefore saving money and down time The flexibility of replaceable parts is a key feature as well particularly for those parts in contact with the product being handled For these reasons most of the components of the machine were designed to be attached with bolts for easy disassembly replacement and assemble process The only component of the machine that was permanently welded is the table structure which is expected to have lifetime durability under normal operating conditions 8 2 Safety and Maintenance Procedure The Safety Information Manual is attached in Appendix G It includes general safety information for machine shop usage of such a machine It is clearly stated in this manual that all personal working with this machine must follow the safety rules explained therein Failure to follow instructions can resul
4. 1 667e 001 8 333e 002 0 000e 000 Stress and Strain analysis results show a very safe and stable table model Deflection Analysis shows that the center of the side of the table is the one experiencing the most deflection yet this value is very small approximately 6 31 10 inch thus the current design it also a good one on this aspect The factor of Safety is very big which is desirable for a machine that is expected to have a long lifespan 5 8 Cost Analysis for One Paddle Below you will find a Table that estimates the cost of producing one paddle with the proposed design the Paddle Maker As it can be seen the cheapest option will imply a saving of 7 75 per paddle when compared with what the actual manufacturer The Gund Company charges Vulcan Materials 13 per paddle Charges which multiplied by the 114 paddles needed for the conveyor belt would represent a saving of almost 884 per paddle shipment Considering that a new set of paddles must be installed every month in order to efficiently load with powder 54 Paddle Maker Machine and Material Selection cement the trucks the total savings for the company would be around 10 606 a year This is only in the Miami Facility If every facility that uses Drag A Flight conveyors today for load product from trains to trucks can save that much money the paddle maker could mean huge savings not only for Vulcan Materials but also for any company in the construction field interested i
5. 7 F TUS P 0 L4 o o 124 5 mes 225 57 2 mm im LES 64 16 2 mem o ol r Notes Stock screw pitches come in 1 in 5 in 25 m and 2 in other screw pitches available upon request Contact Servo Systems Co via phone or e mal for pricing information I SERVO 19 Servo Systems Co 115 Main Road e P O Box 97 e Montville NJ 07045 0097 SYSTEMS 973 335 1007 Tol Free 800 922 1103 Fax 973 335 1661 e www servosystems com 131 Paddle Maker Machine and Material Selection Appendix J Torques Calculation 1 of 2 Fad Ls Necansanuy Tongue frr 2 anie melor Hrtad dupli d X Ind theca I u Pyro 23 6 28 0 0254 m 0 0003 S w lower Sort ada AA ds 0 335 munsured y Wu ae e o 399 28 gt ops Y amp gt AE d cte em F We lo Lb Seca Vecos 24 2 I 64 thee amp t 5 Tab AC 5 LINEAR STAGE Apewa gt Ya Ma worst case Table 3 6 vis gt fe 20 19 Scenario ol vis eathar deca Xay m 0 4254 0 25 2 0 335 ER DE total e c pdn Dr rp nee KE D gt Tow i T m fo secx y Luol IS gas crean Co Coe yens ya T 0 28 7 60 25 0 28 1 08 2 SENE memes tom as 0 453N 4 0 32 1 106 Aie e Ts mme ps 9 32034 qot cule Machen balbo for Vy HP AV 6 2 D x 21 rem s E 4 10 02 6 367 He min Ort w BE data amdi 106 Ny ira Uf zr Te 9 Hes tee nRa 106 fag o 21 gom 0 00037 AP 630
6. Are precision ground for exacting diameter and straightness tolerances Application Type Shaft Type System of Measurement Material Steel Type Finish Surface Finish Hardness Minimum Hardness Depth Rockwell Brinell Hardness Outside Diameter Outside Diameter Tolerance Straightness Tolerance Overall Length Ends Specifications Met Note 148 Linear Motion Shafts Shafts Shafts Inch Steel AISI 1566 Steel Plain 12 rms Case Hardened 0 04 Rockwell C60 1 2 0 0005 to 0 001 0 002 per foot 42 Chamfered American Iron and Steel Institute AIST Are precision ground for exacting diameter and straightness tolerances Compatible Nut Paddle Maker Machine and Material Selection Precision Acme Nuts amp Flanges This product matches all of your selections Part Number 950724145 31 45 Each Compatible Nut Precision Acme Nuts amp Flanges This product matches all of your selections Part Number 950724420 Type Material Type Finish Thread Direction Start Type Acme Size Travel Distance Per Turn Nut Diameter 1 12 Overall Length 75 Speed Ratio Starts 5 1 External Thread Size 9377 16 External Thread Length 50 Hardness Load Capacity Specifications Met Mounting Flange Compatible Threaded Rod Bronze Plain Right Han 1 2710 12 1 300 Ibs Not Rated 95082464 99030470 Round Nut d Thread Fast Travel Multiple Start 70 to 126 Brinell
7. Then Mr Zicarelli from the Engineering Manufacturing Center at Florida International University recommended using Machinist Toolbox which is known computer software to find an estimate of what power would take to cut UHMW PE Using this program it was found the horsepower and torque would be 1 10 HP and 15 OPI respectively Then tests were done using a DeWALT cordless saw Several pieces of the material to be used were cut successfully and then from the specs of the machine the power was found to be 1 20 HP Thus after doing this set of tests a range of power and torque required to cut this material was estimated For simplicity it was decided to use an existing cordless saw and just replace the blade with one for plastics guaranteeing success for the given case For the drilling motor similar steps as those for the circular saw motor were undertaken From the literature survey it was found that similar cordless power drills usually range from 1 20 to 1 5 HP and 50 to 200 OPI for the torques while from the Machinist Toolbox the estimation was 4 HP and 214 OPI To find the correct RPM to operate the drill bit a drill press was used Several holes were drilled letting the speed of the driller vary It was found that anywhere in the range of 700 to 1300 RPM the sheet could be drilled and good finished holes would be obtained Then tests to find torque and horsepower were done by using a Dewaltt cordless drill whose specifications were 1 10 Hp and 10
8. for a smoother surface Figure 47 depicts how the applied force pushed the material more 90 Paddle Maker Machine and Material Selection towards the track inner circle when using ball on disk tester Hence it is difficult to decide where to take the average when the surfaces outside of the groove are not at the same level Also the drop down groove of the tested sample is barely wide enough for the 12 5 micron Stylus technique The stylus has to travel some distance to give accurate results rather than just going through a narrow groove Track Inner Circle Figure 47 Uneven Roughness 91 Paddle Maker Machine and Material Selection 3 An Optical Magnification Microscope Figure 48 0MM MX40 Olympus Optical Magnification Microscope Figure 48 was used as other technique to measure the track depth of the three samples The upper and lower grooved surface was measured using a focus adjustment gradation of 0 1mm minimum per increment Input e A 2000 Magnification Output e New sample First track measured average difference of 16 between upper and lower surface Second track measured average difference of 13 between upper and lower surface e Old sample First track measured average difference of 17 5 between upper and lower surface Second track measured average difference of 20 between upper and lower surface e Orange sample First track measured average difference of 33 between upper and lower surface Second track mea
9. 0 180 0 180 705 16 0 177 NO Interrupted Operation 70 546 17 0173 Ma 0 173 3 NO Surface Marring 70 547 18 0 170 NO Wrapping 70548 19 0 166 25 0 166 av 70545 20 0 161 0 161 NO Cleaning 70530 21 01 0 158 3 NO Melting 70551 22 0157 2 0 157 70522 23 0 154 2 0 154 E 70533 24 0152 2 0 152 FASTE R 70 554 25 01 YA 0 150 3 C LEAN E R 70555 26 0 447 YA 0 147 3 70555 27 0 144 TA 0 144 3 HOLES 70557 28 0141 Tu 0 141 ZA 70538 23 0 135 1 0 136 ZA 30 YA 0 129 RA 70 50 31 0 120 0 120 7 METRIC DRILLS 70 714 3 00 0 118 41 3 00 70 DE 3 50 10 138 a EEJ 7 LETTER DRILLS 70 716 4 00 0 157 54 400 83 PART CED ce SHK DIA OAL 70717 350 0177 EJ 230 BE 7 600 A 0 234 0234 JA 70 718 500 0197 62 500 52 7001 3023 29 0238 n 70715 5 50 0247 71 EE E 70502 C 0 242 EA 0242 4 70 720 6 00 0236 7D 6 00 102 70503 D 0 246 RA 0246 4 70721 6 50 0255 73 530 105 70504 E 0 250 EA 0250 4 70 722 7 00 10 275 73 7 00 105 70 05 F 0257 ZA 0257 45 7072 7 50 0255 7 730 111 70 506 G 0 251 ZA 0261 4 T0724 8 00 0315 EN 800 152 70507 H 0 255 ZA 0255 4 7072 8 50 0335 E as 121 70305 1 2 0272 4 70725 8 00 0354 E 300 124 7005 J 8277 0277 70727 9 50 0374 EJ 350 127 765 K 0 281 2 2281 4 70728 1020 0394 E3 10 00 130 Toit L 029 Ya 0251 E 70728 1050 0413 38 1050 133 70512 M se 0255 na 70730 1100 0433 303 1100 130 70 813 N 0302 EZD 0302 ay 70711 1150 0453 106 1150 143 Tos O 0 316 Pie 03 4 70732 1200 047
10. 1 g0x 33 Moving to sixth hole position Sixth Hole Tapping Drilling Cycle g0z 1 5 g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 g0z 2 g0z 1 95 g0z 2 1 g0z 2 05 g0z 2 2 g0z 2 15 g0z 2 3 g0z 2 25 g0z 2 4 g0z 2 35 g0z 2 6 g0z 1 gOy 40x0 Cutter saw start to cut while drill comes to zero home position gOal4 Sheet moves back one degree when saw finish cutting g0y0z0 Saw and vertical axis of drill assembly goes to zero position g0al6 Sheet moves 16 degrees forward m30 Program finished 76 Paddle Maker Machine and Material Selection 7 1 3 Plan and Recommendation for Material Testing Plan e First we tested the Paddle Maker by using small samples of similar materials such as plastics and thin plywood sheet that are cheaper than polyethylene e Secondly a few sample paddles of different materials can be tested against wear resistance by installing them in the Flight Conveyor belt system e After obtaining a desired material sheet Wear Resistance Test can be conducted to new and current material using an instrument called Tribometer The highly advanced Tribometer offers precise and repeatable wear friction testing The weight loss COF and Volume loss wear properties can be measured after some time The less volume loss and the smaller the COF is the better the material performs under friction e Last a tensile and hardness test will be conducted Recommendation Dr Agarwal Arvind is the head of the plasma
11. Belt Width Outside Diameter Bore Type Finished Bore Pulley Style Bore Size ID W Dimension X Dimension Y Dimension Z Dimension V Dimension Pitch Dia Pitch Pulley Material Note 145 Drive Pulleys Timing Belt Pulleys XL Series 72 Solid Inch 1 4 3 8 4 564 Finished Bore Standard 3 8 9 16 9 16 1 1 1 2 4 584 2 Steel Not flanged Includes set screws Paddle Maker Machine and Material Selection Belts This product matches all of your selections Part Number 6484K228 Form Type Timing Belt Type Material Cord Material Number of Teeth Outer Circle Belt Width Timing Belt Series Pitch Trade Size Color Specifications Met 146 Belts Timing Belts Single Sided with Trapezoidal Teeth Rubber Polyester 90 18 3 8 XL Series 2 180XL Black Not Rated Paddle Maker Machine and Material Selection Appendix P Lead Screws and Linear Shaft GER 4 j gt Catalog 401 gt Find a Branch Search Lu HEEL ror re ones wno cerir oone gt Products gt Resources gt Services gt Worldwide gt Repair Parts gt About Us gt Toda Ball Screw 0 500 In Dia 48 In L Steel Power Transmission gt Bearings gt Precision Ball Screws Precision Ball Screw Ball Screw Dia 0 500 In Lead 0 500 In Right Hand Direction Root Diameter 0 410 In Length 48 In Number of Starts 2 Carbon Steel Material For Use With Ball Nuts 2LGH7 For Use With
12. End Blocks 2LGL1 i FPPPPPPPPPPPRPPPP DDD amus d Item 2LGF1 VH mee a ia a h ha Ha Pieve Price ea 160 75 888888 8 KS Ya Od hd by Brand THOMSON Mfr Model 190 9096CTL48 Ship Qty EI 1 Enlarge Image Sell Qty Will Call 1 Ship Weight Ibs 25 Usually Ships C 1 3 Days Catalog Page No 218 Country of Origin USA Country of Origin is subject to change Additional Compliance amp Required Optional Alternate Information Restrictions Accessories Accessories Products Item Precision Ball Screw Ball Screw Dia In 0 500 Lead In 0 500 Direction Right Hand Root Diameter In 0 410 Length In 48 Number of Starts 2 Material Carbon Steel For Use With Ball Nuts 2LGH7 For Use With End Blocks 2LGL1 147 Paddle Maker Machine and Material Selection Precision Shafts This product matches all of your selections Part Number 6061K73 Application Type Shaft Type System of Measurement Material Steel Type Finish Surface Finish Hardness Minimum Hardness Depth Rockwell Brinell Hardness Outside Diameter Outside Diameter Tolerance Straightness Tolerance Overall Length Ends Specifications Met Note Precision Shafts This product matches all of your selections Part Number 6061K636 Linear Motion Shafts Shafts Shafts Inch Steel AISI 1566 Steel Plain 12 rms Case Hardened 0 04 Rockwell C60 1 2 0 0005 to 0 001 0 002 per foot 48 Chamfered American Iron and Steel Institute AIST
13. G80 G17 G40 G20 G90 G94 G54 G49 G99 G64 G97 Scale i 1 0000 Tool 0 1 0000 Axis Selection Motor Tuning and Setup Velocity Y AXIS MOTOR MOVEMENT PROFILE 468 75 X Axis 421 875 375 Y Axis 328 125 28125 234375 187 5 140 625 93 75 46 875 Recent File 0 Close G Code Load G Code No File Loaded Velocity inches per Minute Edit G Code 08 12 16 2 24 Time in Seconds 28 32 38 4 SRO 100 sf RPM 0 100 Accel Set Next Line Line 0 Run From hiasi 3200 300 5 f0 0129508 fo fo Cancel OK Velocity Acceleration Step Pulse Dir Pulse Steps per In s or mm s per min in s or mm s sec sec G s 1 5us 0 5 S ov EEE 0 Spindle Speed 0j On Off et Reset Emergency Mode Activ m JI JogoworrcwAr 0 G Codes MCodes UnitsMin 0 00 Units Rev 0 PrOTILe S Mach3Mill ReConfiguration Estop Figure 34 Y axis for Saw Assembly Horizontal Direction 71 Paddle Maker Machine and Material Selection Mach3 CNC Controller g x Mill gt G15 G80 G17 G40 G20 G90 G94 G54 G49 G99 G64 G97 Scale 1 0000 Tool 0 s eV 1 0000 Motor Tuning andSeup LT Axis Selection Program Run Alt 1 MDI Alt2 ToolPath Alt4 Offsets Alt5 Settings Alt6 Diagnostics Alt 7 Veloci
14. LDPE approximately 4 times more tensile strength and 3 times more compressive strength HDPE satisfies FDA requirements for direct contact with food HDPE is accepted for USDA and NSF applications including use for meat cutting boards Polypropylene PP is lightweight has high tensile strength impact resistance and resistance to most alkalies and acids It is non toxic with low moisture absorption Applications include die cutting surfaces tank linings cutting boards gasketing and Prosthetic devices LDPE HDPE and PP are thermoformable and require welding vs glueing when fabricating Ultra High Molecular Weight Polyethylene UHMW has the highest impact strength of the Olcfins providing a very low coefficient of friction requiring no lubrication It also has extremely low moisture absorption It is an extraordinary material for industrial uses in wear and sliding applications UHMW is also used in mining paper and pulp processing and in the food and beverage industries Overall applications for Olefins also include bearings conveyor parts wear surfaces gears sprockets feed screws cams liners guide rails feed chutes star wheels drag chain wear strips and mixing paddles and scrapers Availability Many thermoplastics are available in a multitude of forms such as sheets rods and tubes Fabrication The Gund Company can fabricate a wide range of thermoplastic components per the specifications of our customers Please
15. Material Selection Appendix S Machine Shop and Field Snapshots 154 Paddle Maker Machine and Material Selection 155 Paddle Maker Machine and Material Selection 156 Paddle Maker Machine and Material Selection 157 Paddle Maker Machine and Material Selection Appendix T Snapshots Visit to Grainman Corporation 158 Paddle Maker Machine and Material Selection 159 Paddle Maker Machine and Material Selection Appendix U Electronics Set Up x From Driver to Stepper Motors Figure 54 Electronic Controls 160 Paddle Maker Machine and Material Selection 24 V power Converter E Figure 55 Power Supplies Figure 56 Emergency Stop and Controlling 161
16. Not Rated 450 251 to 500 Ibs 1 000 250 to 3 000 20 to 250 F Steel Plastic Not Rated Bearing comes greased Part Number 7208K51 Mounting Style Flange Mount Standard General Purpose Ball 3 8 580 Type Bearing Style Capacity lbs 3 000 Not Rated Maximum rpm Rating Housing Material Steel Plain Steel Steel Up to 250 F Double Sealed Double Set Screw Sets screws included Steel Housing Material Bearing Material Temperature Range Bearing Construction Secures Attaches With Note 144 Paddle Maker Machine and Material Selection Pulleys for Belts This product matches all of your selections Part Number 57105K22 Pulley Type For Belt Type Timing Belt Series Number of Teeth on Pulley Pulley Design System of Measurement For Timing Belt Width Outside Diameter Bore Type Finished Bore Pulley Style Bore Size ID W Dimension X Dimension Y Dimension Z Dimension V Dimension Pitch Dia Pitch Pulley Material Note Drive Pulleys Timing Belt Pulleys XL Series 24 Solid Inch 1 4 3 8 1 3 4 Finished Bore Standard 5 16 1 2 5 8 7 8 7 8 1 528 a Acetal Plastic with Aluminum Hub Includes set screws Pulleys for Belts This product matches all of your selections Xe Part Number 6495K733 Pulley Type For Belt Type Timing Belt Series Number of Teeth on Pulley Pulley Design System of Measurement For Timing
17. Saw Specifications and Features 38 eese 62 Figure Z25 Prototype s MOIOEL aii b oU ette etis n ulii Mea huida Ond i n oM kaakaa 63 Figure 26 Belt Length Determination eile oo besar stake pn zi Multas Gu baec dcus fuu ieiunia 64 Fig re 27 Roller Vale P 65 Figure 28 Shaft Centricity Test Gage code prod iceie eae ro ecu aue PM MU eee 65 Figure 29 Machining of Shaft to Precise Tolerance s wwsmmmmmmnumanimnamanmnammmamanm nima 66 Figure 30 Motor and Linear Stage Assembly eerte acte es ore trep rendus ton ib Qr e acke as abren pad 66 Figure 31 Paddle Maker Team s Total Hours eee eee eene ener enne ennn ne 69 Figure 32 Conector Pins Assignment iisi isi iners aa 70 Figure 33 X axis for Drill Assembly Horizontal Direction esee 71 Figure 34 Y axis for Saw Assembly Horizontal Direction eee 71 Figure 35 Z axis for Drill Assembly Vertical Direction eene 72 Figure 36 A axis for Wheels Angular movement sswsmmsmmanzanaannwnnimnamnnmanimnamanm anna 72 Figure 37 X Y Z A Axis Positive MOVGRIGHL o sepsis i ens Ici ia Vk aia tales Eostk v enM eR UR UP Eo RN eU 73 Figure 38 Double Angle vs Single Alf lb audeas ie is deicteci aquas le pedi E du Ee namana anna 79 Paddle Maker Machine and Material Selection Fig re Ireene 82 Figure 40 Ceramic Abrasive Ball on UHMW PE Disc
18. ZA a 7 5 specially ground at a 60 angle for 70 513 0234 A gradual penetration into the material 70514 nam 270 4 whe eliminating cracking and Toss mle ce wm 45 man re Ween 32 Shipping The C rake angle on the 20517 Wie Jh 3 cutting edge eliminates grabbing 70 520 e 031 1 zi 3 as the drill exits through the 70 521 material producing 70522 Ye 0344 AG zi i acam hae 70523 Se 0355 JA Ts ZA Custom szes can be made p mm mi DA A upon request AM A 4 z i 0531 ole E sss 0625 3 J a 0 656 A 10672 osu Yess 3A AA 07 3 FASTER i AA CLEANER Ri Ram S 3 HOLES oF 700 2a 3 4 6 10757 e 081 34 li THINK 70 554 7 0844 356 70556 76 0 875 24 5 Cms ius is Ao 6 70 558 Fe 0505 JA 6 ONSRUD CUTTER LP Neue mw amp reor dco RIS 70 560 LT 109 3 yA i p 400234 1980 ma NEN S NN P m n 70 552 3 6 Ur www bg one Jesa ens HG Lets Matahworking Technology Group 114 Paddle Maker Machine and Material Selection PART CED CEL SHK DIA 71 C 70530 1 0228 ZA 0228 YA 705 2 0220 ZA 0221 YA 7051323 sony 0213 34 DRILLS 5 7053 zi 0206 A 7053 6 0 204 0204 WITH aa 70537 8 0155 Ze 2 198 ZA 70 536 s 01 ha 0 136 SPECIAL gt 70 540 11 0181 0 191 3 POINT zE 70542 13 0 185 0 185 3 7053 14 0 182 70 54 15
19. applied Figure 20 Location oo in Untitled e ET 7 0 0 Deflection in 0 03746543 0 1609954 Slope j deg D 1609954 50 0 Moment Ib in Shear Figure 20 Deflection Analysis of Linear Shaft 5 7 Material Analysis for Machine Assemblies Structural analysis involves the consideration of physical properties in the effort to predict and study the response of a structure to the adversities of the environment in which it is operating Involving the fundamental of material failure theories mechanics as well as non static loading the fundamental goal of structural study is the estimation of stresses internal forces and physical deformations This portion of the engineering design process has become essentially important as a result from the demand to save money in the realization of direct testing 51 Paddle Maker Machine and Material Selection When building any kind of machinery it is of great importance to estimate the life span of the design by predicting failure using theoretical analysis Structural analysis to all possible components was done using SolidWorks Cosmos Works in order to determine their performance under continuous applied loads Finite element analysis was used to make sure the structure is safe Obtaining a high factor of safety will guarantee reliability of the Paddle Maker and minimize vibrations Furthermore Deflection Analysis was applied to deter
20. based mineral oil which can cause slight irritation when in contact with skin The major environmental impact to be considered relates to oil waste Grease should not be disposed into water When it floats on water it eliminates the oxygen from being transport into the water and hence causes death for fish and other marine life It is the user s responsibility to dispose the grease in according with state regulations and use approved containers meeting OSHA requirements All plastic chips generated from the machining of the paddles will be recycled Plastics are a man made product and therefore it can and must be reused A recycling program from an 96 Paddle Maker Machine and Material Selection vendor specializing in this field should be employed by the user so the machine will not have a negative impact on the environment 8 4 Risk Assessment In the United States machine safety and healthful working conditions for employee are regulated by Occupational Safety and Health Administration OSHA This administration provides information on installation of machine safety and proper guarding A few organizations have their own regulation however those must as be firm as OSHA standards In addition to OSHA other organizations such as the American National Standards Institute ANSI provide information on construction care and use of machine tools This information is published as B11 standards Certain standards are developed for specific
21. do not hesitate to call or fax us your requirements All of the information suggestions and recommendations pertaining to the properties and uses of the products herein are based upon tests and data believed to be accurate however the final determination regarding the suitability of any material described herein for the use contemplated the manner of such use and whether the use infringes any patents is the sole responsibility of the user There is no warranty expressed or implied including without limitation warranty of merchantability or fitness for a particular purpose Under no circumstances shall we be liable for incidental or consequential loss or damage 106 Paddle Maker Machine and Material Selection The Gund Company Inc St Louis Missouri Tel 314 423 5200 Fax 314 423 9009 Material Data Sheet Item Polyolefins Typical Properties Physical Properties Specific Gravity Specific Volume cu in per Ib Refractive Index Tensile Strength PSI Elongation 96 Modulus of Elasticity in Tension 10 PSI Compressive Strength PST Flexural Strength PSI Impact Strength ft Ib per in of notch Rockwell Hardness Thermal Conductivity Specific Heat cal per C per gm Thermal Expansion 001 per C Resistance to Heat F continuous Heat Distortion Temperature F Volume Resistivity Electrical Properties Dielectric Strength short time 1 8 thick Dielectric Strength step by step 1 8 thi
22. down left and right Mach3 is easy to setup and it has many great features which are easy to understand Figure 23 Some features used in Mach3 are G Code display M Code display spindle speed control relay control The program can control Lathe mills Routers Lasers Plasma and even engrave 60 Paddle Maker Machine and Material Selection D Artseft m cest Ro e em eem Imp M rmm Figure 23 Mach3 Screen Shot Features 39 6 2 8 Saw Assembly A motor from a DeWALT circular saw was used to drive the carbide blade that cuts along the length of the raw material The following table was developed for some of the commercially available power saws The cheapest of all these options was the third choice however the HP of this machine is too large for the required application thus the DeW ALT Cordless Circular Saw was selected Details of this selection are shown in table 4 and Figure 24 Table 4 Power Saws Comparison 38 Kett Electric Plastic Cutting Saw K 224 35377 10 5 2500 Plastic amp 0 8046 RIGIDCircularsaw NA 9 00 15 3000 Framing 180 24138 61 Paddle Maker Machine and Material Selection DC390K 6 1 2 165mm 18V Cordless XRP Circular Saw Kit Product Features e 3 700 RPM for fast rip cuts and cross cuts e 6 12 carbide tipped blade for 2x cutting capacity at 90 and 45 High strength magnesium shoe and upper guard provides increased durability
23. ee Ma UE 45 Table 3 Paddle Production Cost eee 55 Table 4 Power saws Comparison Pave 61 Table SENE ie m Aa 67 Table Initial Design A P eat 68 Table 7 Wear Measurements for Double and Single Angle Paddles sssss 79 Table 8 Axis Function and Direction cicsesscavesvastevessaniccevwsnavesdiadescasastesensasnaeaevasbavnssascaszatessoed 128 Table 9 Tribometer Data Sample ueste traten iwa 141 10 Paddle Maker Machine and Material Selection Nomenclature Symbol Description Units UHMW PE Ultra High Molecular Weight Polyethylene N A RBT Rail Barge and Truck N A RH Relative Humidity Jo UMT Universal mechanical Tribology Tester N A PP Isotactic Polypropylene N A PFD Percent Fast Decay Jo COF Coefficient of Friction N A R amp D Research and development N A MR Millions of Rads unit of radiation MR USPTO United States Patent and Trademark Office N A OMM Optical Magnification Microscope N A LVDT Linear Variable Differential Transformer Mm 11 Paddle Maker Machine and Material Selection Abstract Construction paddles are an important part of the functioning of the Drag a Flight Conveyor shown in Figure 51 of Appendix D These conveyors are devices through which powder cement is transported from rail cars to trucks and the paddles are an essential part of the conveyor system However
24. for an automated plastic cutting drilling and saw machine using US patents web sites 28 led to no results for these specific combined functions The new paddle maker machine is a unique design for a very particular application that will indeed save time and money to any company using Drag a Flight Conveyor Even though the design has a low cost and provides a unique application the team has no intention of filing for a patent at this point since this project was supported and thus intended for the Miami facility of Vulcan Material Furthermore the possible clients soliciting for this 41 Paddle Maker Machine and Material Selection machine is limited which makes profiting from it a risky venture In addition the Paddle Maker is composed of many different mechanisms that have long been patented namely drills circular saws roller table and CNC workstations which could also make obtaining a patent even harder 4 4 Commercialization of the Final Product In order for The Paddle Maker to be commercially ready many different parts need to be optimized for instance the drilling assembly motor and the two lead screws of the saw and drilling assembly respectively The prototype presented in this report was built just to demonstrate that our design works thus some parts were substituted to be able to meet our budget In order to transform this prototype into a commercially viable product the drilling motor needs to be substitute
25. for long term cut accuracy e 0 50 bevel capacity provides additional capacity for multitude of applications e Fan cooled motor with replaceable brushes for maximum power and durability e XRP extended run time batteries provide long run time and battery ife Specifications Warranty Information This DEWALT High Performance Industrial Tool comes Voltage 18V with a warranty package that includes No Load Speed 3400 e 90 Day Money Back Guarantee Blade Diameter 6 1 2 e 1 Year Free Semice Contract e 3 Year Limited Warranty Bevel Capacity 0 50 ER sr More information on the general DEWALT warranty Depth of Cut at 45 1 5 8 The DC390K Includes Depth of Cut at 90 2 1 4 e 1hour charger e 18V XRP battery Tool Weight 8 7ibs e Carbide tipped blade Shipping Weight olds s ven Figure 24 Circular Saw Specifications and Features 38 6 2 9 Drill Motor Through an extensive search of similar motors on the market and while performing tests of our own as explained in the Design section it was found that the motor needed to have at least 1 10 HP and 100 ounces of torque per inch Following this criterion some commercially available motors were selected as shown in the Appendix L yet their prices range from 300 to 400 Hence for the purpose of this prototype the motor shown below was used in part because it has 1 8 HP and also because it was a donation from the team s sponsor Vulcan Materials 62 Paddle Maker Machine and Materi
26. get back stocked due to the lack of producers and the inconsistency of the orders Expectations are to solve this problem by building a machine to fabricate these paddles The paddles need to be 3714 long 12 thick and 134 wide and with six holes 7 16 in diameter each spaced by a distance of 52 in between The current design of the paddle also features an angle cut in one of the sides to decrease friction This machine needs to be autonomous and to be able to produce the paddles from a given sheet of raw material Thus 13 Paddle Maker Machine and Material Selection the machine will need to first convey the sheet of raw material to the place where by meansofa mechanical system the holes will be drilled Then a circular saw being moved by a stepper motor will do the cutting Finding a material that is resistant to friction and has a better guality to price ratio than polyethylene is also one of our main objectives In addition our goal will be to modify and strengthen the wear of the current paddle material and test it in the field The paddles are made of Ultra High Molecular Polyethylene which has the highest impact strength among all classes of plastic products Even though it is an extraordinary material for industrial uses in wear and sliding applications it wears fast in the current function This can be observed in Figure 50 Appendix C 1 2 Motivation Vulcan Materials Miami Quarry division offers mining processing a
27. objective conditions and specifications of the output product the challenge presented in designing structures goes beyond the scope of this project Based on practical knowledge information gathered from numerous sources and the help of computational software such as SolidWorks Beam 2D 3 1 and Excel a logical design and analysis of the here presented structure and mechanism was conducted Some preliminary analyses were done and are presented in the following section of this paper Selecting major components for the machine being designed was a fundamental step in the task of designing and engineering a working device that could operate under the presented restrictions and conditions Some of the factors considered for component selection were the cutting speed and the feed speed of the drill bit For the construction of the frame standard rectangular 2 x1 tubing was used in combination with several other small structural steel parts Several pieces were made of aluminum to reduce weight cost and to increase durability of the completed mechanism The selection of the main electrical components for this machine was a challenge that was directly discussed with the team advisor other professors and several of our electrical engineering colleagues before buying the motors and controller kit 43 Paddle Maker Machine and Material Selection Fundamentals of mechanics of materials and material properties were applied in the search for a material
28. the materials commonly sliced by water jetting while tempered glass diamonds and certain ceramics cannot be cut with it The versatility precise cutting and clean finish of abrasive water jet machining displayed in Appendix E Figure 52 avoids the need for expensive secondary finishing However our team believes that due to the material being soft and precision not a big factor appropriate cutting could be done using conventional cutting tools such as a circular saw This tool can easily be found in any of the major hardware stores such as Home Depot Ace Hardware or Grainger 20 Paddle Maker Machine and Material Selection After doing an extensive search and literature review a company that manufactures machinery with similar processes and principles as those of the Paddle Maker was found Its name is Kaltenbach 30 a 4 generation family owned company and a world leader in metal sawing technology The company uses CNC for steel beam drilling and metal fabricating Figure 4 The CNC features contain vertical and horizontal drilling units with a combined saw Figure 2 A spindle has three axes for drilling with an option to change the tool automatically on each axis A computer control interface allows the integration of the sawing operation In addition the company has a CNC robotic machine designed for coping beams and square tubes One of its features is material fed pusher conveyor Figure 3 Figure 3 Hinged Roller Conveyor 3
29. the speed and torque twice as fast as that of the 12 volt one Stepper motors step from one position to the next and their coils are constantly energized As a results when running at certain speed they are prone to vibration Motor dumper 58 Paddle Maker Machine and Material Selection or changing acceleration helps remove vibration The Rockcliff driver board uses a PFD adjustment setting to help remove resonance Motor Drive NN h Sa Power Supply Stepper Motors Figure 21 High Performance 4 Axis CNC Motor V10 Drive o Qi Boc Figure 22 Schematic Diagram for Rockcliff V10 59 Paddle Maker Machine and Material Selection 6 2 7 System s Software PC based CNC software the Mach 3 series available from Artsoft USA is used to run the Paddle maker machine Rockcliff provides a special file name Rockcliff4X XML to configure Mach3 software settings to the motor drive board Mach3 features and functions are easy to use Mach3 provides tutorials that cover basic knowledge installation and configuration as well as many troubleshooting videos Mach3 minimum computer requirements are not supported by Laptops due to inherent power saving features To use the features and run the machine accurately a desktop PC was used which outputs more consistent voltages to its parallel port pins One of the features provided by Mach3 is to allow us to use the G code program language in order to move the motors up
30. these paddles are made of polyethylene and due to friction against the frame of the machine they wear out quickly and are expensive Due to the lack of vendors producing the required cut to length product orders usually get back stocked and companies end up paying extra shipping fees and delaying their operations In an ever expanding society like ours in which new buildings and houses are constructed every day this is unacceptable To improve this situation a machine that autonomously produces these paddles was developed The design will allow for the interested companies to produce them in house with little effort great efficiency and at a lower price As part of our project testing with new more friction resistive materials was conducted The objective of this project is to find the best material possible for the task at hand and have the best price to quality ratio in addition to building an autonomous machine to produce these paddles under 2000 The prototype has been designed to employ a combination of several mechanical and electronic systems to accomplish the final output product The major systems included in the prototype were a drilling system a cutting mechanism and a rolling table all of which are equipped with the appropriate electronic controls Some elemental components used in the prototype were bought and the great majority custom built by the members of the team with the support of the FIU students machine shop to meet
31. to perform the drilling of the six holes which is mainly due to the chosen setup of the assembly and the speed of the stepper motors Also the table was built to fit one specific size of sheet 3714 by 38 thus the machine is limited to this size of raw material bigger sheets would have to be cut to size before being input into the Paddle Maker Future work will solve this issue by having an adjustable table workstation 2 3 1 Paddle Material The current paddle material is UHMW PE This material is good for friction resistance and has proven to perform adequately when used in Flight a Drag Conveyors Thus our team tried to find a material similar or better to the one being currently used and that is economically feasible It was found that UHMW PE can be in fact improved when exposed to different procedures explained in detail in the materials section of this report 25 Paddle Maker Machine and Material Selection 3 Design Alternatives 3 1 Overview of Conceptual Designs Developed The process of developing and selecting several conceptual designs for the desired machine that would produce the needed paddles was a crucial step in the advancement of this project During the first stage of brainstorming many ideas defining the reguirements were considered while keeping in mind the end product reguirements After recording ideas for several days the first informal drawings were discussed and several changes were recommended as everyon
32. types of machine tools Standards in the B11 series that are related to this project include B11 1 Mechanical Power Presses B11 8 Drilling Milling and Boring Machines B11 10 Metal Sawing Machines Purchasing the ANSI B11 XX Machine Tool safety Package is expensive Therefore a Safety Manual attached in Appendix G includes safety information that was gathered using OSHA website and related links Also FIU Machine shop safety manual was used as a reference Safety Information Manual for the Paddle Maker Machine is attached in appendix G It includes instruction for Installation Operation and Maintenance on Conveyor Drilling and Sawing operations 97 Paddle Maker Machine and Material Selection Conveyors are one of the best productivity tools available to warehouses and industrial facilities However employers are losing millions of dollars each year due to conveyor related injuries The United States Department of Labor Bureau of Labor Statistics reports around fifty workplace fatalities a year where conveyors are the source of injury In general conveyors are safer than other material handling alternatives if they are maintained and designed properly To address the concern of conveyor related injuries the safety information below must be considered by the employers 1 Since guards make up one the most common types of safety devices used for the protection of conveyors they have to be maintained regularly In a
33. 0 21 Paddle Maker Machine and Material Selection Figure 4 Drilling Assembly 30 A local business Grainman Machinery Corporation was visited to check for systems that could relate to our proposed machine design The Company supplies equipment for the grain industry and has several old and new machines some of which are very similar to the design of the here presented machine Some pictures of conveyors with end processes like bag sawing and bag sealing are shown in Appendix T 2 Project Formulation 2 Project Objective As mentioned earlier this project will be based on two central objectives First the development of a fairly simple machine capable of making these paddles from a sheet of raw material while maintaining a lower cost per paddle Secondly as time allows our team desires to optimize the current material being used and find a more efficient cost effective one The current paddle material provided by the Gund Company has a tensile strength of 2 500 PSI However in an effort to obtain a better wear resistance UHMW PE it was found that the current vendor can provide the same material having the same specific gravity with a higher tensile strength of 5 500 PSI One of the objectives was to apply a gamma radiation process to an UHMW PE sheet as time allows Since cross linking has been shown to improve the wear 22 Paddle Maker Machine and Material Selection resistance of ultra high molecular weight polyethyl
34. 0 OPI Combining this information it was decided that a motor capable of providing 1 8 HP and 170 OPI was acceptable Yet this motor speed was much greater than needed so as part of the assembly a gear pulley system was included to reduce the 47 Paddle Maker Machine and Material Selection speed of the assembly to approximately 1300 RPM which is the fastest speed achieved in our testing while still obtaining quality holes Since the stepper motors torque requirements for the roller table and the linear stage were the ones expected to be higher than those used in the horizontal movement of the saw assembly and the drilling assembly a kit was purchased to exceed the specifications of the higher torque component in this case the linear stage 17 7 OPI The drill assembly and saw assembly require less torque due to their providing displacement in the x direction and not carrying as much load and having two high precision rods and bearings supporting them The kit bought was a great decision since it saves us time and money A single package provided us with everything needed for controlling the displacements of the machine a driver four 270 OPI stepper motors one power source and a controlling board Another major reason why these steppers were chosen is because their compatibility with the mounting of the linear stage 5 5 Dynamic Vibration Analysis The team consulted Dr Levy on how to conduct vibration analysis on the system Dr Lev
35. 10 Literature Survey Nestor Jorge Orena Design Calealation gt EEEE ection amp Testing F rare oriai Em Construction gt Machine Testing Orena Jorge ur Presentation gt gt Report Preparation Figure 18 Project Timeline 4 2 Team Breakdown of Responsibilities Tasks and Roles The timeline and responsibilities table is an approximation of the time spent in the different tasks and it only reflects the most important subjects The team members names appearing in the arrows just represent the person in charge of that specific category The team members tasks reflected below just show the team member s main responsibilities however every member participated in every specific area and in the report as a whole The table below shows the approximated number of hours each member spent for each category 39 Paddle Maker Machine and Material Selection Table 1 Numbers of Hours Spent Machine Design Material Search ie e A WO l OIN IA Material Test Machine Components Ordering 61 Er NE E E Report Structure and Contents Total Hours 4 3 Patent Copyright Application 83 58 55 26 2 4 48 46 48 Nn gt u CA 393 389 For an invention to be patented such idea needs to be novel and the inventor must show how the invention works In addition it is important to keep records of all details including drawings brainstorming and dates of importance To e
36. 127 0 0125000 0 1449698 0 596038317 0 0135333 0 141012291 0 599369831 0 0143167 0 14351177 0 599369831 0 0153500 0 138929391 0 598461237 0 0161333 0 147469279 0 598461237 0 0169167 0 152259948 0 599975561 0 0179667 0 149760468 0 599975561 0 0187500 0 137887942 0 598764102 0 0195167 0 14392835 0 599066966 0 0205667 0 157467196 0 601489886 0 0216000 0 156634036 0 602095616 0 0223833 0 157467196 0 599975561 0 0231667 0 149552178 0 599369831 0 0242167 0 157467196 0 600278426 0 0250000 0 162882735 0 601187021 0 0260333 0 157467196 0 601489886 0 0268167 0 150801918 0 600581291 0 0276000 0 155800877 0 600581291 0 0286333 0 162882735 0 603912806 0 0294167 0 167256823 0 604821401 0 0302000 0 162257865 0 603004211 0 0312500 0 155384297 0 602095616 0 0320167 g 0 162466155 0 602398481 0 0330667 0 169964593 0 603307076 0 0338500 n 0 166007084 0 603307076 0 0346333 0 166215374 0 601489886 0 0356667 0 161216415 0 600278426 0 0364500 0 168089983 0 602095616 0 0372333 I 0 174963551 0 604215671 0 0382667 0 172672362 0 604215671 0 0390500 0 169548013 0 601792751 0 0401000 0 164549054 0 601792751 0 0408833 0 173297232 0 604821401 0 0416667 0 17912935 0 605124266 0 0427000 E 0 17787961 0 603307076 0 0434833 0 166631954 0 602701346 0 0442667 E 0 171422622 0 604518536 0 0453000 0 1780879 0 605729996 0 0460833 0 174963551 0 605729996 0 0471333 A 0 165
37. 2 111 1200 143 70515 P 0323 73 1250 0452 114 1250 70 15 Q 0 332 Ae 03322 4 7073401300 0512 114 1300 152 70517 R Zn 2338 Fr 1358 0531 122 1350 188 70218 S 0 348 3 0348 47b 70736 1410 0551 122 1400 168 7051 T 0358 PEA 0358 ZA 70737 1420 0571 12 1450 158 70 520 U 0 368 3 2368 5 70738 1525 0550 132 15 00 181 TTEN V 0377 35 0377 70739 1550 0690 132 1550 181 70522 W 0 385 3 0385 zu 7 740 16 00 0630 132 16 00 181 70523 X 0357 EA 0357 SA 70741 1650 0550 1550 181 70 624 Y v 0404 70742 1710 0569 1700 194 70 625 Z 0 413 Fa 0413 E 70 743 17 50 0583 143 1750 194 115 Paddle Maker Machine and Material Selection the ONSRUDadvantage PLASTIC SAWING 70 400 SERIES Saw Blades with Unique Geometry for Cutting Plastic Materials Special application blades for phenolic hard and soft plastic matenals Premium performance design results in cool clean cutting without chipping or melting Blade design is optimized for either thick or thin material PRODUCT OFFERING CAL MATL THICKNESS DMAMETER VERF PLATE mcn MM Jmosi NM veers camo m MM me MM anon 70402 X X 2 10 10r 250 60 MATB 0126 32 0 087 22 70 404 x 4 10 100 10 250 20 Tos 0 126 320 057 22 x REESE 1 SE RET DS 70 405 e 2 10 17 300 72 MATE 0 126 32 0 057 22 70 408 4 10 100 12 300 22 Tos 0 126 32 0 087 22 TCG Trip
38. 2 4 6 ft length 1018 Carbon Steel 989804375 6 ft length Type 304 Stainless Steel 3145 Ei Type Material Type Finish Thread Direction Start Type Acme Size Travel Distance Per Turn Nut Diameter Overall Length Speed Ratio Starts External Thread Size External Thread Length Hardness Load Capacity Specifications Met Mounting Flange Compatible Threaded Rod Round Nut Bronze Plain Right Hand Thread Fast Travel Multiple Start 12 8 T 1427 15 8 1 9377 16 50 70 to 126 Brinell 1 300 Ibs Not Rated 950824642 99030A400 6 ft length 1018 Carbon Steel 98980A183 6 1 length Type 304 Stainless Steel 149 Paddle Maker Machine and Material Selection Appendix Q Vibration Analysis 1 of 3 150 Paddle Maker Machine and Material Selection Paddle Maker Machine and Material Selection Paddle Maker Machine and Material Selection Appendix R Rockcliff Pin Assignment inum mo ckclsFIrF E TT RACHEL m STROBE LPT GND x X AXIS STEP 1 STROBE OUTPUT Y X AXIS DIRECTION 10 INPUT z Y AXIS STEP 11 INPUT A Y AXIS DIRECTION 12 INPUT COM Z AXIS STEP 13 INPUT Z AXIS DIRECTION 14 OUTPUT A AXIS STEP 15 INPUT A AXIS DIRECTION 16 OUTPUT INPUT 17 OUTPUT INPUT INPUT INPUT OUTPUT INPUT OUTPUT OUTPUT GROUND GROUND GROUND GROUND GROUND GROUND GROUND GROUND ojo NiO nsw n 153 Paddle Maker Machine and
39. 219 d 62025 9 Veit A dee ona Ve en 21 0325 525 132 Paddle Maker Machine and Material Selection 2 of 2 o gt 2 hiyo Edo YI YA Hilding uns Bar Wary nq eg Ei Aia y 0 025 FELI z BE 9 Hin Car A x 05x BY CO da E gt W 22 515 ks m s 72 8194 N Merens I Porvermerene T nete S Ms Ts sse Y jo 0 9 5Y m itae A 20 2 fre skule gt amp feLvctheLE NE ji eb J2 Q 1 ec 0 44 Fy rpm f 0 44 S AI 3 boo ts Ad As 0 lai i kana fler 7 Lu ape mes Tr 7 0 233 y 2 202 28 94 Wa 0 051 H P WE LE AI 0 co 133 Paddle Maker Machine and Material Selection Appendix K Deflection Analysis of Linear Shaft The following data was the input parameters and the corresponding results obtained from Beam 2D BEAM LENGTH 40 0 in MATERIAL PROPERTIES Steel AISI 4140 N Modulus of elasticity 29000000 0 Ib in Stress limit 95000 0 Ib in CROSS SECTION PROPERTIES Moment of inertia 2 0 003067962 in 4 Top height 0 25 in Bottom height 0 25 in Area 0 1963495 in EXTERNAL CONCENTRATED FORCES 10 0 Ib at 20 0 in SUPPORT REACTIONS Fixed at 0 0 in Reaction Force 5 0 Ib Reaction Moment 50 0 Ib in Fixed at 40 0 in Reaction Force 5 0 Ib Reaction Moment 50 0 Ib in MAXIMUM DEFLECTION 0 03746543 in at 20 0 in No Limit specified MAXIMUM BENDING MOMENT 50 0 Ib in at 0 0in 50 0 Ib in at 40 0 i
40. 3 6 Design Process Diagram 3 6 1 Material Selection Logic Diagram Iteration Figure 16 Steps for Material Optimization Process 36 Paddle Maker Machine and Material Selection The optimization process involved the four steps mapped above and detailed as follows Step 1 Recognized the need the improvement of the product obtaining a better friction resistant material is the most important part of the entire process Step 2 Research material for new current test this part of the process included finding a product with similar or improved properties to that of polyethylene Step 3 Test the new material after receiving the material it was tested and compared to polyethylene wear Step 4 Improve the design As a result of the test performed on the new material quantitative measure were obtained and results are presented in following sections 3 6 2 Proposed Machine Design Logic Diagram Figure 17 Machine Design Process Step 1 The machine was designed such that the plastic sheet will be easily rolled over a platform roller table to the drilling area 37 Paddle Maker Machine and Material Selection Step 2 A table workstation consisting of two linear stages and a drill system moved by stepper motors were designed to create holes on the plastic sheets Step 3 A saw moving by means of a linear stage and stepper motor cuts the paddle to required dimensions Also a round corner router not included in the
41. 590504 0 604821401 0 0479167 E 0 169756303 0 605124266 0 0486833 0 176421581 0 606335726 0 0497333 E 0 183086859 0 606638591 0 0507667 0 182461989 0 605427131 0 0515500 0 169756303 0 603609941 Table 9 Tribometer Data Sample 141 Paddle Maker Machine and Material Selection Appendix O Bearings Gears and Belt Specification Drilling Stage oil hole ic stati G MI B inch inch inch WI z n nn TWA 687 1 00 2 00 3 50 1 25 B 1 12 1 37 1 68 GE SAN HES ig 142 Paddle Maker Machine and Material Selection Sawing Stage Bearing TWASU 687 1 000 2 000 1 68 1 251 25 1 12 1 37 1 6 ra 1 0 BARR mu 5 Een 143 Paddle Maker Machine and Material Selection Ball and Roller Bearings This product matches all of your selections Part Number 6384K363 Type Ball Bearing Style Ball Bearing Type System of Measurement For Shaft Diameter Outside Diameter Width Flange Outside Diameter Flange Thickness ABEC Precision Bearing Rating Dynamic Radial Load Capacity lbs Dynamic Radial Load Capacity Range Ibs Maximum rpm Maximum rpm Range Temperature Range Bearing Material Seal Material Specifications Met Note Mounted Bearings This product matches all of your selections ABEC Precision Bearing Flange Mount Type For Shaft Diameter Dynamic Radial Load Ball Bearings Flanged Double Sealed General Purpose Inch 1 2 1 3 8 1 2 1 1 2 1 16
42. 90L Lab Manual WII Safety FIU EMC Safety Manual doc FIU Machine Lab safety manual 25 www OSHA gov OSHA Guidelines 26 www technet unsw edu au tohss web 20files drillpress 1 pdf Drill Press Safety 27 http safety ucanr org Video Saws Grinder Drill 28 http patft uspto gov US patent search website 29 Grainger catalog Purchase machine components 30 http www kaltenbachusa com saws and equipment structural fabricating KD drilling machines default html 104 Paddle Maker Machine and Material Selection 31 Singiresu S Rao Mechanical Vibration 3 addition Addison Wesley Publishing Company USA 1955 32 Dewalt catalog Saw specification 33 http www machsupport com Art Soft Mach 3 software 34 Mcmaster catalog Purchase components 105 Paddle Maker Machine and Material Selection 12 Appendices Appendix A Paddle Material Data Sheet The two following data sheets were obtained from the user manual of the RBT The Gund Company Inc Tel 314 423 5200 St Louis Missouri Fax 314 423 9009 Material Data Sheet Item Polyolefins Description A class of plastics produced as Low and high Density Polyethylenes Polypropylene and Ultra High Molecular Weight Polyethylene UHMW Low Density Polyethylene LDPE is an excellent material for chemical uses in low heat applications providing good toughness resistance to chemicals and flexibility High Density Polyethylene HDPE is more rigid than
43. 95 The Gund Company Inc Ya x 38 x 48 216 250 Horn Plastic Inc With Crosslink Process Ya x 60 x 96 242 285 5 3 2 Machine Major Components The proposed system is composed of several mechanical and electrical components that work simultaneously to achieve the targeted end product The major components are as follow e Beginning with a DC electric motor that provides rotational motion to the drill assembly e A DC motor that provides rotational motion for the saw assembly e A belt and timing gear system that transfers the rotating motion and torque from the motor to the drill bit assembled in a custom made shaft e The drill bit shaft has a simple chuck machined on it so that the drill bit can be removed if necessary This shaft was machined to custom fit the existing assembly to reduce vibrations created by centricity differences e A drill bit specially design for drilling hard and soft plastics e High speed bearings that support the shafts holding the chucks 45 Paddle Maker Machine and Material Selection e Four stepper motors that provide linear motion to the drilling workstation in the vertically and horizontally direction and to the cutter in the horizontal direction parallel to that of the drilling and rotational motion to the roller table e A6 circular saw powered by an electric motor to make the horizontal cut to the desired width e Atable composed of several rollers where the
44. Maker Machine and Material Selection Appendix H Paddle Maker s User Manual Paddle Maker s User Manual In the following document the steps necessary for the user to effectively operate the Paddle Maker Machine are named and explained Figure 53 Paddle Maker Prototype Be advised that using this machine may cause harm if safety precautions and instructions in this manual are not followed Please refer to the Safety Manual also attached in this report for further details Also note that for an accurate cut given the nature of UHMWPE that this machinery should be inside a closed facility kept at room temperature to avoid deflection and dust in the work piece In between paddles have an employee dust the work piece with a pressure air hose It is of great importance to know beforehand the direction and purpose of each axes For this refer to the table below 127 10 11 12 Paddle Maker Machine and Material Selection Table 8 Azis Function and Direction drill horizontal movement tothe rigth Saw horizontal movement tothe rigth drill vertical movement sheet mover clockwise Operation Routine Do not Turn Power On Check that the sheet of UHMWPE is in the starting position by the end of the roller table being pressed by the rubber wheels of the table mover mechanism Assure that the screw connections between the computer and the driver in the hardware box are not loose Verify that the saw s blade is in good con
45. Test eeeeeen 82 Fe 4l Test ed S BUD BS eec iuern tacite ci n ras Coa Rasni ES RASNE 82 Figure 42 Wear Volume Loss Comparison eese nennen nnnm nennen 83 Figure 43 Coefficient of Friction Comparison eese nennen emeret 84 Figure 44 Volume Loss Formulas 4 a iia reir eon ta eben E Pa eub tetro ctus jade ua ciu a abu 85 Figure ge ke EE iae eio iiie sia 90 Figure 46 Average Delta Surface Roupliess m nesnstmmesmneiejnjenstudmneiedietan 90 Feire 47 Lueyen Rourmess p a2vv4eqeariesassgmsmnivteg egene AR 91 Figure 48 OMM TT TS 92 Figure 49 Travel Time Using Precision Lead Screw 2 uoi tnit ato oneness 94 Figure 50 New vs Damaged PaSOdleiseeeoitttoti trahebant In aa Sete dita esee broaden eee 111 Figure 51 Drag a Flight Conveyor from RBT Luvaerseussrndgrmnmssnnesnderedameaje nn 112 Figure 52 Precise Cutting Clean and Smooth Finish of Water Jet Machining 113 Figure 53 Paddle Maker Prototype iu siete nett e tende edecend aba pnta tud pU adele accede 127 Fe HR avden 160 Figure S5 POWer Supp les P een 161 Figure 56 Emergency Stop and Controlling aac c2ccsccccscensccnscicasrescanssccenveccuancenureeasonaccansieesesseaneeness 161 Paddle Maker Machine and Material Selection List of Tables Table 1 Numbers of Hours Spent 2d pete tes el euci irae eciqun n cuesta mi ees x Mira tcu anena 40 Table Z LEHNDW CoStar Sel eR EINER EUIS ERR ae UTD MN pu M
46. Velocity Acceleration Step Pulse Dir Pulse 0 Steps per In s or mm s per min in sormm s sec sec Gis 1 Sus 0 5 Run Erom hiasi 200 s 0 010307 fo fo Cancel OK Units Rev 0 00 T J JI Jog ON OFF Ctrl Alt J ReConfiguration Estop Profile Mach3Mili Close G Code Load G Code RPM 0 S ov Spindle Speed Units Min 0 00 a i On Off Reset Emergency Mode Activ Zinnibit GCodes M Codes 0 000 Figure 36 A axis for Wheels Angular movement 72 Paddle Maker Machine and Material Selection 7 1 2 G Codes lt MR Figure 37 X Y Z A Axis Positive Movement Simple G code shown below was written and loaded to Mach3 software and used as follow e The A axis rotates in the given amount of degrees 15 causing the sheet to move forward the 1 75 width of paddle e The first hole tapping drill cycle starts at zero X and at Z 1 5 coordinates e The drill assembly goes up to Z 1 coordinate e The drill assembly moves to X 5 5 to second hole position e Second hole tapping starts e The cycle continues for a total of 6 holes The paddle center hole is not drilled e Cutter saw start to cut and moves Y 40 while the drill comes to X 0 zero home position e The sheet mover wheels go from an angle of 15 to 14 when saw finishes cutting to guarantee that no contact takes place e Sa
47. X axis assigned to the drill assembly and the Y axis assigned to the saw assembly both move in the horizontal direction The Z axis move the drill assembly vertically and the A axis rotates the wheels that move the sheet forward 70 Paddle Maker Machine and Material Selection Mach3 CNC Controller g x Program Run Alti MDIAN2 ToolPathAlt4 Offsets AtS Settings Ait6 Diagnostics Alt Mil gt G15 G80 G17 G40 G20 G90 694 G54 G49 G99 G64 G97 Motor Tuning and Setup Axis Selection X AXIS MOTOR MOVEMENT PROFILE Neos X Axis Velocity inches p Y Axis ELM A Z Axis P No File Loaded AA 173 077 115 385 Edit G Code FE Recent File 0 0 pa 08 12 1B 2 24 28 32 55 4 Close G Code Time in Seconds Load G Code Accel I Set Next Line Velocity Acceleration Step Pulse Dir Pulse Line o Steps per In s or mm s per min in s or mm s sec sec G s 1 5us 0 5 Run Erom Hasa 2500 300 5 f0 0129508 Jo fo S ov On Off Reset Emergency Mode Activ Zinhibit JI dog ON OFF Chalii I Units Min 0 00 Spindle Speed G Codes M Codes 0 000 4 0 00 ReConfiguration Estop Mach3Mill Figure 33 X axis for Drill Assembly Horizontal Direction Mach3 CNC Controller Pr x Program Run Alt 1 MDI Alt2 ToolPath Alt4 Offsets Alt5 Settings Alt amp Diagnostics Alt 7 Mill G15
48. a lod idend teal terii io ud 132 Appendix K Deflection Analysis of Linear Shaft seseeeeeeee 134 Appendix L Drill Motor Options ee eseeesecsseeesecesseecaeceseeesneeeaeecsaecsseessneesaeeseaeeaeenses 135 Appendix M Material Lab NOteS wsssmenmnimanmanmnmznamnmnimanmnm anaimani 139 Appendix N Material Testing Data Samples serene 141 Appendix O Bearings Gears and Belt Specification eese 142 Appendix P Lead Screws and Linear Shaft eerie rtt meer Stet obstet sep iadd 147 Appendix Q Vibration Analysis samen rb insu e ens s asa eo tpa Did ties RU Ea ugs 150 Appendix R Rockcliff Pin Assignment eu inre cerro rr Setter aptare code Fera h nsene 153 Appendix S Machine Shop and Field Snapshots eee 154 Appendix T Snapshots Visit to Grainman Corporation esee 158 Appendix U Electronics Set Bj m 160 Paddle Maker Machine and Material Selection List of Figures Figure 1 Si3N4 Ball and UHMW PE Disk Contact Schematic 1 esses 17 Figure 2 Kaltenbach s Drill Cutting Roller Table 30 iei rr ubt rr ph Ev Re epu ia e er rpdd eo 21 Figure 3 Hinged Roller Conveyor 30J wswmmnmanmnmenamanznnmanzna nni nmnannmnimnamanm aina 21 Figure 4 Drilling Assembly 30 mi E EEE 22 Figure 5 Circular Saw Workstation Design Alternative swsswmmnmena
49. a material with better performance The theoretical design of the prototype was not very complex With the assistance of several computer software and the knowledge acquired in the course of our studies the most relevant engineering analyses were conducted and the results are presented in this report The final prototype was decided upon after analyzing all the alternatives discussed in the Design Alternatives section After considering all factors of interest it was decided to build the presented design which was called Paddle Maker This decision took into account aspects such as machine cost production cost per paddle design reliability part availability construction time environmental impact and safety After all the dedicated work by each member of the team was combined the results can be seen on a functional machine that performs the required tasks The team realizes that there are still several aspects of the project that can be improved such as changing the whole thread rods by lead screws and replacing the drill motor by a more suitable one This would allow for smoother running of the system and as a result the production time will be decreased and the machine and motor life extended 100 Paddle Maker Machine and Material Selection Further testing and optimization of both the paddle and the Paddle Maker are an ongoing process since there are a few suggestions that can be implemented as explained in the Future Work section
50. al Selection Figure 25 Prototype s Motor This motor has a speed of 3600 RPM thus a gear reduction system was added to the assembly to bring down the speed to about 1200 RPM which was proven to be an effective drilling speed yielding good quality holes in this material Two gears were purchased to accomplish this The following drawing indicates the considerations for determining the correct belt dimensions 63 Paddle Maker Machine and Material Selection Figure 26 Belt Length Determination 6 2 10 Roller Table The roller table was designed and manufactured to meet the size and functionality of the cutting process Structural analyses were presented in prior sections although the table was expected to surpass design requirements and this was proven by the large factor of safety obtained from these analyses The roller table was designed so that the distance between rollers gradually increases along the length of the table By doing this we are decreasing the torque required for this stepper motor to move the sheet Thus the motor would have to work less and therefore its lifespan would likely be extended Calculation details are included in Appendix J 6 3 Construction Construction of the machine was a very intensive and challenging task where our knowledge and hands on abilities were put to the test The roller table Figure 27 was built by welding steels beams to form a frame 48 in length and 39 in width Then the rollers wer
51. annmanimnamanm amma 28 Figure 6 Round Corner Roller avse Mee eg Be ee 28 Figure 7 Mechanical Drilling Assembly Design eene nennen 30 Figure 8 Drilling Workstation DeSlgti iuae i o eterna bota a Rees tu ines ideni etu see ba reu G ment 31 Figure 9 Roller Table Design Alternative suuaesnsaesneseatdnssnneizniijeieenennsmniie 32 Figure 10 Automatic Table Design Alternative Trimetric View see 33 Figure 11 Automatic Table Design Alternative Inclined View see 33 Figure 12 Overall Dye lu e aa WA 34 Figure 13 Section View of Proposal Design ai ace nerit torn erac epit nea pinu edem p Ec red Uudd a 35 Figure 14 Exploded View of Proposal Design w2cccccesccsigssccsstensocsacesiucnssedeanseecnenyssteicnesatescecnstedeeneds 35 Figure I5 Targeted Finished Paddle aaa 36 Figure 16 Steps for Material Optimization Process rennen 36 Fipure 17 Machime Design Process vaasersenkassdekes Headset eur a 37 Figur 18 Proj ct TN ia 39 Figure 19 Dunkerley Formula Used for the System Lerma rodea oi ru amwe 49 Figure 20 Deflection Analysis of Linear Sbaluansmeobsresesdngemdieujenseamdngndlljess 51 Figure 21 High Performance 4 Axis CNC Motor V10 Drive eee 59 Figure 22 Schematic Diagram f r Rockcliff VID Lise et eee Ree rn bue cesta ida Reuse fo amma 59 Figure 23 Mach3 Screen Shot Features 39 rre pert ete theta eoo URe vn va Lo nee VP een EE mamaa 61 Figure 24 Circular
52. at re SUE VC T c aa 15 1 3 1 MAU EE 16 1 3 2 Plastic Cuttiris Machines EE atu en ue eaim ido bb S cud aUi esae Lu dta es 19 2 Project Formulation oneeoseesexssexees sssuss AA 22 2 1 rds o 22 22 Design Nes 23 22 1 Motor Selection ae eee prd nbn 23 2 2 2 Drilling CO Lee 24 2 2 3 Movement viii je 24 2 5 Constraints and Limitations EE EE 25 2 3 1 Paddle Material 25 2 Desin MSN 26 3 1 Overview of Conceptual Designs Developed eene 26 AGE ET eee 26 3 2 1 Design Alternative 1 Water Jet Robotic Platform sees 26 3 2 2 Design Alternative 2 Laser Cutter wwwwwmmmmammmwem Y Ree repre s de ra aw 2T 3 2 3 Design Alternative 3 Circular Saw Workstation eeeeeeee 27 3 3 SPA TH HH 29 3 3 1 Design Alternative 1 Mechanical Drilling Assembly s 29 3 3 2 Design Alternative 2 Drilling WorkStation wsswmmmmanmnmmmamnmnnmzaza 30 34 Sirius dni T 31 3 4 1 Design Alternative 1 Roller Table ww wmmmmenmnmmmamanmnimamnmawmaa 31 3 4 2 Design Alternative 2 Automatic Material Handling Table 32 3 3 Feasibility ASSSSSIIDE een 33 Paddle Maker Machine and Material Selec
53. bly would take longer than that of the final design presented in the next section Figure 7 Mechanical Drilling Assembly Design 3 3 2 Design Alternative 2 Drilling WorkStation The last major design explored was a CNC like system also referred to in this report as a drilling station Figure 8 The concept of CNC goes back to the 40 s and 50 s when the combination of existing machines with electrical controls started to become popular The rapid development of electronics in the last few decades has affected the CNC technology accordingly This has revolutionized the manufacturing industries making almost every process faster more accurate and consistent A great deal of knowledge has been gathered by industries through all these developments and a considerably large number of applications are in use today making the components of CNC available in almost every possible form The concept discussed for this project was based on the combination of a cutter and a drill mounted on two linear motion systems moved by stepper motors and controlled by a driver connected to a computer Some of the concerns when discussing this design were the price of accurately controlling the position of 30 Paddle Maker Machine and Material Selection the drill when moving from one position to the nezt and the constant movement of the electrical wires connected to all the moving devices Figure 8 Drilling Workstation Design 3 4 Material Moveme
54. by the wear mass loss using an electronic scale having 0 01mg accuracy e Specific wear rate Ms determined by Msz dead nl Where Mw is mass loss of worn disc Mc is mass loss of dipped disc and n is number of tests X reciprocating lt gt Z carriage Sinusosial loading Srain gauge sensor UHMWPE Si3N4 ball disc V Y reciprocating Figure 1 Si3N4 Ball and UHMW PE Disk Contact Schematic 1 17 Paddle Maker Machine and Material Selection A different study conducted in China University was related to friction and wear behavior of nitrogen ion implantation on UHMW PE 3 A UHMW PE disc was put in contact against a ZrO ceramic ball The disc rotated and the ceramic ball was fixed on the load arm The electrical motor was controlled by frequency converter The tribometer tester measured the tribological behaviors of ion implanted UHMW PE against ZrO ceramic The results showed that nitrogen ion implantation improved the hardness of the surface of the material and increased friction coefficient values Test parameters and material selection for N implantation were e UHMW PE disc of 5mm thickness and 45mm diameter e Surface polished to 0 3 um e ZrO ceramic ball of 3mm diameter e Contact load SN e Sliding speed was 0 19 m s e Human plasma as lubricant e Test time 110 minutes for dry friction and 200 minutes for plasma e Room temperature RH 55 e UHMW PE implantation acce
55. ck Dielectric Constant 60 cycles Dielectric Constant 10 cycles Dielectric Constant 10 cycles Dissipation Power Factor 60 cycles Dissipation Power Factor 10 cycles Dissipation Power Factor 10 cycles Arc Resistance Seconds Chemical Properties Water Aborption 24 hr 1 8 in thick Burning Rate Effect of Sunlight Effect of Weak Acids Effect of Strong Acids Effect of Weak Alkalies Effect of Strong Alkalies Effect of Organic Solvents Clarity Polyethylene Hi Molecular Weight Average Value 0 940 0 942 29 8 2 500 5 25 1 02 No Break R38 7 2 163 10 710 680 230 0 0002 0 01 Very Slow Very Resistant Translucent to Opaque All of the information suggestions and recommendations pertaining to the properties and uses of the products herein are based upon tests and data believed to be accurate however the final determination regarding the suitability of any material described herein for the use contemplated the manner of such use and whether the use infringes any patents is the sole responsibility of the user There is no warranty expressed or implied including without limitation warranty of merchantability or fitness for a particular purpose Under no circumstances shall we be liable for incidental or consequential loss or damage Paddle Maker Machine and Material Selection Proposed material from the same vendor but with beter wear resistance MANUFACTURERS OF The Gu
56. ck Sample New LL 5 0 6 RR E o 0 4 4 9 0 2 o 0 0 0 50 100 150 200 250 Sliding Distance m Figure 43 Coefficient of Friction Comparison 7 2 2 Paddle Maker Calibration Calibration of the machine was done to assure that the right functioning of the Paddle Maker was obtained Through Trial and Error all the stepper motors were calibrated so that the optimum speed and movement s distances were achieved It took a few paddles for the machine to get calibrated but the end result was a coordinated machinery where all subassemblies worked together as one Paddles produced by this machine were of good quality and accuracy 7 3 Evaluation of Experimental Results 7 3 1 Material When testing different materials using a tribometer coefficient of friction weight loss and volume loss can be measured and compared Comparing these parameters shows which 84 Paddle Maker Machine and Material Selection material has better wear resistance characteristics Using the tribometer tester in the plasma lab at FIU data for three samples was obtained and compared Volume loss formulas are shown in Figures 42 Volume data was obtained from excel using LVDT column for depth h The LVDT gives voltage signal when there is a small displacement The h data points were calculated as follows The first points up to where the graph starts having a trend of steady state were not considered because in the beginning of the test there is a transien
57. d lifespan of the machine A round corner router needs to be added to the saw assembly so that the side angle can be obtained since it will be mounted in parallel to the saw the same stepper motor will move the whole assembly Most raw material suppliers provide sheets of up to 102 inches long therefore the rolling table could be extended to handle longer sheets of raw material The circular saw blade used in this prototype should be substituted with one especially made for cutting soft plastics Appendix F that would provide a better finished cut The drill motor can be replaced with one that is more suitable for that task as shown in Appendix L thus increasing the durability of the machine yet rising its price A system that would allow for the collection of the produced paddles needs to be developed so that production of many paddles can be achieved in an organized and fast manner The team proposes to built a slider mechanism that would attached to the end of the machine where paddles are output and through which the paddles will slide down to a collection table All the electronics should be optimized by electrical engineer since it was designed using elemental knowledge of circuitry and electricity The main elements that need to be looked at are the wire sizes power supply selection and motor efficiency 102 Paddle Maker Machine and Material Selection 11 References 1 Shirong Ge Shibo Wang Norm Gitis Michael Vinogrado
58. d with the one suggested in Appendix L also the whole thread rods need to be substituted with lead screws shown in Appendix P so that both the saw and drill assembly run smoothly and more accurately Also a slider table as proposed in the future work section should be included to the machine as an accessory to be able to collect the paddles 4 5 Discussion Management is one of the most important tasks of any engineering project Weekly meetings were held to discuss tasks to be accomplished and to ensure that the Table of Responsibilities was being followed in a timely manner Different tasks were split between members according to their abilities yet the more intensive tasks like design construction optimization and testing were mostly accomplished by group work Cost was an important factor affecting nearly every decision throughout the realization of this project To meet the budget and time deadlines some concessions had to be made as mentioned in section 4 4 and Future Work in 42 Paddle Maker Machine and Material Selection section 10 yet because of having had a well timed and organized breakdown of tasks our prototype was successful and both the machine and the paddles met expectations 5 Engineering Design and Analysis 5 1 Structural Design Structural design and analysis in the engineering process of creating functional machinery are extremely important steps that need to be revised thoroughly Sometimes restricted by the
59. ddition warning signs must be readable 2 Conveyors operate using power transmission Items such as gears shafts and belts are common to all conveyors therefore they must be guarded from exposed power equipments to prevent accidents Typical items to be guarded include Drive Guards for chain v belt and gearing Guards can be constructed of different materials such as expanded metal solid sheet metal and plastic They must be securely fastened to the conveyor framework Coupling Guards to be provided when they are used to connect shafts They must be assembled around the connections between motors and gearboxes End Shaft Guards They must be assembled in order to prevent items from becoming caught in shafts In particular the protruding ends of the rotating shafts are dangerous 98 Paddle Maker Machine and Material Selection A table saw is one of the most dangerous pieces of eguipment in a workshop An increased awareness for caution is needed while working with a saw blade This sharp multi toothed blade usually spins at high rpm therefore care is required when working near the blade According to the US Consumer Product Safety Commission there are approximately 60 000 injuries each year related to saw blades Another cause of table saw accidents is what is called kickback Kickback happens when the blade catches the material and throws it back towards you Kickback can be caused by a variety of different things i
60. del to life and in the process a lot of material would be needed thus the price of developing this model would be high 32 Paddle Maker Machine and Material Selection Figure 10 Automatic Table Design Alternative Trimetric View Figure 11 Automatic Table Design Alternative Inclined View 3 5 Feasibility Assessment Research of all these possible options while keeping in mind cost availability complexity and material being handled among other factors led us to choose the design presented below As can be seen the roller table was chosen for moving the work material and the CNC like approach using lead screws and stepper motors was used for both the drill and sawing 33 Paddle Maker Machine and Material Selection station This design was the most time effective and cost efficient approach for doing a Paddle Maker machine Figure 12 Overall Design Some small details are not included in this drawing A section view of the first draft is shown below 34 Paddle Maker Machine and Material Selection Figure 13 Section View of Proposal Design Next an exploded view Figure 14 is presented to help identify the different components Ne that make up the whole assembly Figure 14 Exploded View of Proposal Design 35 Paddle Maker Machine and Material Selection A drawing of the finished paddle Figure 15 was done to help visualize the needed proccesses Figure 15 Targeted Finished Paddle
61. dition and well adjusted Check that the drill bit in the drilling assembly is operable Connect both the machine and computer plugs to the outlets Turn on the computer and open Mach 3 Loader Load the G code attached in section 7 1 2 of this report Make sure that the four axes X Y Z A are in their respective home positions NOTE If axes are not at home position then follow the section Moving the axis to home position below Turn the saw and drill SWITCHES ON On The Monitor click Start Cycle on Mach 3 Carefully supervised that the machine is functioning adequately and that the final product paddle quality is good 128 Paddle Maker Machine and Material Selection ATTENTION If needed STOP the cycle using the ESC button on the keyboard or STOP icon in the Mach3 interface or by pressing the EMERGENCY BUTTON in the electronic box at the right side of the machine 13 When there is not enough material left to do one more paddle the machine should be stopped and a new sheet of material will be replaced 14 Repeat steps 1 13 Moving the axis to home position If moving an axis to his home position is required then the following steps are to be followed e Goto MDI tab in the Mach3 interface e In the input line write GO x0 yO z0 a0 all axis should move to their initials positions e If they are not then you need to input GO followed by the axis and the distance wished to be moved until the zero initial posit
62. drochloric acid Hydrogen peroxide Hydrogen sulphide Lactic acid Magnesium chloride Mercury Methanol Methyl ethyl ketone Methylene chloride Mineral oll Motor ol Nanc scd Nzodenzen gt e Oleic acid ozone Perchloric acid Petroleum Phenol Phosphoric acid Potassium chromate Potassium hydroxide Potassium nitrate Polystone M UHMW PE 40 204 Potassium permanganate Pyridine Sea water Sodium carbonate Sodium chloride Sodium hydroxide Sulphuric acid Tallow Tetranydrofurane Tetralin Thiony chloride Toluene 110 10 10 60 75 M I Paddle Maker Machine and Material Selection Appendiz C New vs Damaged Paddle Figure 50 New vs Damaged Paddle 111 Paddle Maker Machine and Material Selection Appendiz D RBT Drag A Flight Conveyor Prag A Fight Conveyor MODEL 3629 Figure 51 Drag a Flight Conveyor from RBT 112 Paddle Maker Machine and Material Selection Appendix E Water Jet Machining Illustration Figure 52 Precise Cutting Clean and Smooth Finish of Water Jet Machining 113 Paddle Maker Machine and Material Selection Appendix F Drill Bit and Saw Blade Description HSS PLASTIC DRILLS 70 502 0 125 14 r ker aa Onsrud s high speed steel drills are wa LI 0 156 17 3 designed to produce holes in hard and A i soft plastic while eliminating edge 5e 0 1 e 3 hipping and chip im Ed P 70 512 Ae 02
63. e in weight loss for the cross link material Volume Loss Results e The sample data for volume loss was as follow Old sample 2 14 mm 1 74 mm New sample 28 00 mm 26 54 mm 86 Paddle Maker Machine and Material Selection Orange crosslink sample 1 65 mm 22 19 mm Because of the difference in the volume loss values for the orange sample another track test done and volume loss measured 26 76 mm Figure 42 depicts a lower volume loss for the old material when compared to the new and cross link material For each sample old and new both tracks were similar in values The Orange sample had one low and one high value and the test was repeated one more time The third test had high value Only the higher values were considered for the orange sample It could be some experimental error which gave such lower value for the first test Discussion and Conclusion In general a lower COF and a lower volume loss shows better wear resistance The results comparison for the three samples was not as expected The Cross linked and the new material samples have higher COF and higher volume loss than that of the Old material However the weight loss measurements showed an increased in value and questions arose about the test method After further research about the subject we understood that the UHMW PE material does not always experience weight loss when using the ball on disk type test Sometime it is just compressed and the densi
64. e installed to allow for easy displacement of the raw sheet of material 64 Paddle Maker Machine and Material Selection Figure 27 Roller Table For the construction of the motor assembly Figure 30 some elemental machining was done by one of the team members and the centricity of the gear shaft was checked using a deflection gage Figure 28 After doing this it was realized that the gear shaft was off centered by 0 002 due to the differences in diameter between the bearing inner cup and the shaft A new shaft was machined to fit the inner diameter of the bearing to solve the centricity issue Figure29 Figure 28 Shaft Centricity Test Gage 65 Paddle Maker Machine and Material Selection Figure 30 Motor and Linear Stage Assembly For both the drilling and the sawing assembly two supporting rods and one lead screw attached to a stepper motor were used for movement of the assemblies A Dewaltt 18 V circular saw was used for cutting For further detail refer to sections 6 2 8 and 2 2 3 66 Paddle Maker Machine and Material Selection 6 4 Prototype Cost Analysis This section reflects the total price of buying the parts materials and tools that were necessary for the realization of The Paddle Maker Machine Table 5 below represents the approzimate total cost of the final design Table 6 shows the cost analysis of manufacturing the machine using the mechanical drilling assembly instead of the drilling workstation The
65. e in the team agreed Because the machine is composed of three subsystems namely drilling roller table and cutting the conceptual design section is also divided into three sections that expose different approaches to designing the Paddle Maker 3 2 Cutting 3 2 Design Alternative 1 Water Jet Robotic Platform The first design discussed was a robotic platform equipped with a water jet specially designed to cut through the materials selected in the Material Selection part of this report Water jet systems typically have very unique capabilities that make them more advantageous and effective over traditional machining Their ability to cut while keeping low temperatures makes them practically attractive to industries handling flammable materials such as natural gas and petroleum In addition material cut by water jet has a smooth satin like finish Although highly efficient and popular in industrial applications where versatility is an essential factor these modern systems have complex controls and functionality and are relatively expensive Since our 26 Paddle Maker Machine and Material Selection application does not reguire high accuracy and because of the high cost of this alternative it will not be considered for our design 3 2 2 Design Alternative 2 Laser Cutter Another typical system widely used in modern manufacturing to cut almost any type of material and discussed while brainstorming was laser cutters Basically las
66. e nine rollers were modeled as rods experiencing the same deflection hence they were considered in parallel The frame of the roller table was divided into frame and frame w and both were modeled as fixed beams with a thin walled thickness cross section The legs frame and rollers can be taken as in series since they all experience the same load e Drilling assembly The two support rods are considered fixed and the lead screw is considered as a free rod The drill station which includes electrical motor stepper motor rods and linear bearings are considered as one mass The two rods and lead screw carry the same load namely the weight of the assembly thus they are considered to be in series 49 Paddle Maker Machine and Material Selection e Sawing assembly Includes the same parts as the drilling assembly The only difference is the length of the rods and lead screw The saw blade and motor are considered as one mass The rods and lead screw carry the same load namely the weight of the assembly thus they are considered to be in series e Sheet mover assembly the stepper motor and wheels move the sheet to be cut to length very slowly The wheels only turn approximately 3 4 of a revolution to move the sheet the prescribed distance and thus this assembly including its respective motor is deemed stationary and is excluded from the vibration analysis though its mass is included in the roller s table mass gt The total natural freque
67. e the blade or counterclockwise to lower it NOTE Use a shallow depth setting when cutting thin materials in order to obtain a cleaner cut 3 Adjusting bevel angle Loosen the lock lever counterclockwise and turn the hand wheel until the desired angle 0 45 is obtained The bevel angle is indicated by the arrow pointer After obtaining the desired angle tighten the lock lever clockwise to secure the adjustment CAUTION After adjusting the bevel be sure to tighten the lock lever securely 4 Adjusting positive stops The tool is equipped with positive stops at 90 and 45 to the table surface To check and adjust the positive stops proceed as follows Move the hand wheel as far as possible by turning it Place a triangular rule on the table and check to see if the blade is at 90 or 45 to the table surface If the blade is at an angle shown in Fig A turn the adjusting screws clockwise if it is at an angle shown in Fig B turn the adjusting screws counterclockwise to adjust the positive stops 5 Switch action This tool is equipped with a special type of switch to prevent unintentional starting To start the tool first depress the switch lever While keeping it depressed pull its lower portion toward you To stop the tool press the lower portion of the switch lever CAUTION Always use work helpers such as push sticks and push blocks when there is a danger that your hands or fingers will come close to the blade Always hold the wo
68. ear depth with a maximum load of up to 60N 7 1 4 Theory Testing The usage of angles on both sides of the paddle was tested since it was unclear whether having angles on both sides instead of one would make a difference on the wearing of the paddle Thus a double angle was done manually to three of the existing paddles and they were mounted in the conveyor along with the regular one sided angle design After a month in the conveyor all the paddles experienced the same friction and wearing action They were dismantled from the 78 Paddle Maker Machine and Material Selection conveyor and three of the one sided angles were compared to the three with two sided angles Results are shown in the table and figure below seems to demonstrate that the second angle does not contributes to the wearing of the paddle which makes sense since this side is not in contact with the frame of the conveyor itself as opposed to the other side angle that is in contact with the moving material in this case powder cement Table 7 Wear Measurements for Double and Single Angle Paddles Measurements inches Angle Effect on Paddles Double 1 E Double 2 i Double 3 width inches gt Single 1 Single 2 Single 3 New Middle Figure 38 Double Angle vs Single Angle 79 Paddle Maker Machine and Material Selection 7 2 Test Results 7 2 1 Paddle Material Comparison An extensive search f
69. ed maximum long term service temperature based on practical field experience Specimens 1 8 thick x 2 diameter or square 108 Paddle Maker Machine and Material Selection Appendix B Data Sheets From Different Vendors Vendor 1 Interstate Plastic aterial Datasheet _ Quadrant EPP TIVAR 1000 Natural Virgin UHMW PE Physical Properties Metric English Comments Specific Gravity 0 93 g cc 0 0336 Ib in ASTM D792 Water Absorption Max 0 01 96 Max 0 01 96 Immersion 24hr ASTM D570 2 Water Absorption at Saturation Max 0 01 Max 0 01 Immersion ASTM D570 2 Mechanical Properties Hardness Shore D 66 66 ASTM D2240 Tensile Strength Ultimate 40 MPa 5800 psi ASTM D638 Elongation at Break 300 300 ASTM D638 Tensile Modulus 0 689 GPa 100 ksi ASTM D638 Flexural Modulus 0 758 GPa 110 ksi ASTM D790 Flexural Yield Strength 24 1 MPa 3500 psi ASTM D790 Compressive Strength 20 7 MPa 3000 psi 10 Def 73 F ASTM D695 Compressive Modulus 0 552 GPa 80 ksi ASTM D695 Shear Strength 33 1 MPa 4800 psi ASTM D732 Coefficient of Friction 0 12 0 12 Dry vs Steel QTM55007 Limiting Pressure Velocity 0 0701 MPa m sec 2000 psi ft min 4 1 safety factor QTM 55007 Izod Impact Notched NB NB ASTM D256 Type A Electrical Properties Surface Resistivity per Square Min 1e 015 ohm Min 1e 015 ohm ASTM D257 Dielectric Constant 2 3 2 3 1MHz ASTM D150 Dielectric Strength 90 6 kV mm 2300 V mil Short Term ASTM D149 Dissipation Factor 0 0005 0 0005 1MHz ASTM D150 Th
70. em anymore reducing delays to a minimum and boosting its productivity in this part of the facility This could represent savings of more than ten thousand dollars a year at the Miami Quarry division alone Finding the right paddle material and creating a machine that manufactures them represents a real life solution to a challenging industry problem There is a need for improvement and we are ready to answer the call with extraordinary effort and dedication while employing knowledge and resources gathered in the course of our engineering studies 1 3 Literature Survey Several terms processes and or machines whose understanding is of great importance for the realization of this project are mentioned throughout the report Familiarity with these terms was essential for the realization of this project UHMW PE Ultra high Molecular Weight Polyethylene has one of the highest impact strengths of any thermoplastic and has excellent abrasion resistance tensile strength energy absorption stress resistance and friction coefficient properties In this section an overview of the work done on improving the material s performance by other engineers and scientists will be reviewed In addition there is a need for an in house machine that can make paddles out of this material A large UHMW PE sheet will have to undergo various processes including drilling and cutting Also means for conveying this raw sheet material need to be incorporated into the machi
71. ene 2 we investigated the wear loss of radiation cross linked material The development of the machine presented in the conceptual design of this project was the central goal of this project while at the same time research for a better material was conducted as mentioned above In the process of developing this machine several sub objectives arose and as they were executed they enhanced the central topic of this project A few existing technologies used in the manufacturing of plastics were explored to learn crucial information about this topic Improving the cost of the end product by exploring different vendors and material properties was one of the major objectives underlying our main tasks Concentrating on building a functional mechanism that will perform the above mentioned tasks while keeping the complete process at a cost efficient price and safe environmental conditions was the focus of this project 2 2 Design Specifications In this section all the specifications gathered while designing the system are presented Specifications are separated into different categories for better understanding 2 2 1 Motor Selection Throughout this project when selecting motors many questions arose What kind of motor should be used DC AC or stepper motors What Torque and Power are these motors going to need to accomplish their respective tasks What RPM will they need to run at To answer all of these questions an extensive literature survey wa
72. entional Starting Make sure switch is in off position before plugging in Never stand on tools 118 Paddle Maker Machine and Material Selection 14 Plug in the Tool Using a power source with voltage less than the nameplate rating is harmful to the motor 15 Extension Cord Make sure your extension cord is in good condition When using an extension cord be sure to use one heavy enough to carry the current your product will draw An under sized cord will cause a drop in line voltage resulting in loss of power and overheating 16 Manager must be notified immediately if broken tools are found or if the machine is not operating correctly 119 Paddle Maker Machine and Material Selection Conveyor Safety SAFTEY INFORMATION Un dA UO N me INSTALLATION Interfacing of Equipment When two or more pieces of equipment are interfaced special attention shall be given to the interfaced area to insure the presence of adequate guarding and safety devices Guarded by Location or Position Where necessary for the protection of employees from hazards all exposed moving machinery parts that present a hazard to employees at their work station shall be mechanically or electrically guarded or guarded by location or position When a conveyor passes over a walkway or work station it is consider guarded solely by location or position if all moving parts are at least 8 ft 2 44 m above the floor or walking surface or are other
73. equires motor configuration outputs for step pin number and direction pin number Mach3 software is compatible with the Rockcliff CNC motor driver The figure below shows the pin assignment for the four steppers motors per Rockcliff manual The configuration is attached in Appendix R Mach3 CNC Controller j g x perator Plugin Cont Program Run Alt4 MDIAI ToolPath alts Offsets Aits Settings Al6 Diagnostics Alt7 x anon oo AAA Port Setup and Axis Selection Motor Outputs input Signals Output Signals Encoder MPG Spindle Setup Mil Options Dir Pin Dir Port Signal Enabled Step Pin in Step Low A Step Port X Axis bi Y Axis X NA A A Z Axis A Axis Edit G Code BAG Recent File Close G Code Load G Code C Axis oleo wo xu ele ele uuu X X ON ON XN ON X elele ew eles elele e e spine owes 11 409 9 fc RPM 04 Spindle Set Next Line Run From Here So AI On Off 8 i i I prs o Spinde Speed Active Z Inhibit Jog ON OFF Ctrl Alt J is G Codes M Codes 0 000 Units Rev o Sai Mach3Mill Figure 32 Conector Pins Assignment Part of the setup was to obtain the correct velocity and acceleration for each stepper motor Figures 32 35 below are movement profile screenshots for X Y Z amp A axis The
74. er cutting consists of a high power laser guided by a computer to burn a groove in the material near the emitting component The material being removed can be melted by the high temperatures and or blown away by high velocity fluids usually gases Laser cutters present several advantages over the majority of the traditional cutter systems conseguently making them especially popular as an innovative emerging technology They produce extremely smooth surfaces as well as very precise cuts and usually cut fairly fast if the material thickness is not extreme The single most attractive characteristic of a laser cutter is the lack of physical contact between the tool and the piece being worked on completely eliminating the wear and tear factor present in traditional processes Furthermore laser cutting requires considerably high electric power thus increasing the operation cost of the machinery Because the main objective of this machine is to reduce the paddle cost it is not feasible to include this technology into the machine given that high precision is not required 3 2 3 Design Alternative 3 Circular Saw Workstation The cutting along the width will be done by a circular saw blade specially designed to cut plastic Figure 5 This particular blade has unique features like the sharpening of the tooth that allows for a cleaner and faster cut which makes it highly efficient when cutting plastic The width of the cut done by the blade is also a paramete
75. er s manual before operating the Saw Direction of Feed Feed work into a blade or cutter against the direction of rotation of the blade or cutter Check for damaged Blade before operation Ask a technician to replace cracked or damaged blade immediately Watch for Vibration that could indicate poor installation 8 Use blade guards 9 Minimize the blade height Ensure the height is 4 to below the gullet 124 10 11 12 13 14 15 16 17 Paddle Maker Machine and Material Selection Do not wear gloves Gloves cause a loss to your sense of touch as well as a possible loss of gripping power Lower Blade When Work is Done After finishing your work the saw blade should be lowered below the table Use a sharp clean blade Never freehand a cut Stop Button Ensure that the stop button is easily accessible Turn off the saw before removing small cut off pieces Use eye and ear protection Do not reach over the saw blade when it is running This puts you off balance and you could slip into the blade MAINTENANCE CAUTION Always be sure that the tool is switched off and unplugged before attempting to perform inspection or maintenance 1 Cleaning Clean out chips from time to time Lubrication Keep the saw in running condition at all time to assure maximum service life Lubrication places Threaded shaft to elevate the blade Elevation guide shafts on motor 125 Paddle Maker Machine and Ma
76. ermal Properties CTE linear 68 F 216 pm m C 120 pin in F 40 F to 300 F ASTM E831 Thermal Conductivity 0 409 W m K 2 84 BTU in hr ft2 F Melting Point 135 C 275 F Crystalline Peak ASTM D3418 Maximum Service Temperature Air 82 2 C 180 F Long Term Deflection Temperature at 1 8 MPa 264 psi 46 7 C 116 F ASTM D648 Flammability UL94 Estimated Rating HB HB 1 8 inch Qualitative Processing Properties Compliance FDA Compliant Machinability B s 1 10 1 Easier to Machine Service in Alcohols Acceptable Service in Aliphatic Hydrocarbons Acceptable Service in Aromatic Hydrocarbons Unacceptable Service in Chlorinated Solvents Acceptable http quadrant matweb com SpecificMaterialPrint asp bassnum P 1smp00 10 26 2009 109 P i addle Maker Machine and Material Selection Vendor 2 RPlastic com R CHLING Engineered Plastics e M nt g Engineering Plastics and R chling Machincd Plastics M UHMW PE CHEMICAL PROPERTIES Polystone M Chemical Properties Chemical Resistance Aceteldehyde Acetic acid Acetone Acrylonitrile Ally alcohol Aluminum chloride Ammonia Ammonium chloride Aniline Benzaldehyde Carbon disulphide Carbon tetrachloride Chlorine gas Chiorobenzene Chlor form Chromic acid Citric acid cyclohexanol Cyclohexanone Dekalin Dibutyl phthalate Diesel fuel Diethyl ether Dioxane Ethanol Ethyl acetate Ethylene chloride Ethylene diamine Polystone M UHMW PE Glycerine Hy
77. es the rollers were bought and the table frame built Also a Torque analysis was done to find the required torque needed to move the sheet forward by a stepper motor Details are found on Section 6 and in Appendix J named Torques Calculation To move the drilling assembly up and down a linear stage was acquired Selection criteria for this element were a travel distance of at least 2 inches and to be able to carry at least nine pounds which is what our drilling assembly weighs Also a torque calculation was done to be able to select an appropriate stepper motor To move the drilling assembly in the x axis a much smaller torque would be required since the weight of the 24 Paddle Maker Machine and Material Selection assembly would be supported by two high precision shafts and the whole thread rod that moves the piece The same applies to the stepper motor that moves the circular saw assembly horizontally Thus a kit of four stepper motors was purchased to meet the highest torque requirement given by the vertical linear stage By buying them together we guaranteed the functioning of the system would be appropriate and the cost of the machine is reduced 2 3 Constraints and Limitations Constraints and limitations were explained in detail in the previous subsections where the specifications for every component of the machine were discussed Some of the limitations not discussed previously were that the drilling station would take about 2 minutes
78. essories shall be locked or tagged out in accordance with a formalized procedure designed to protect all person or groups involved with the conveyor against an unexpected start DO NOT lubricate conveyors while they are in motion Only trained personnel who are aware of the hazard of the conveyor in motion shall be allowed to lubricate Maintain all guards and safety devices IN POSITION and IN SAFE REPAIR Maintain all warning signs in a legible condition and obey all warnings 121 Paddle Maker Machine and Material Selection Saw Blade Safety SAFETY INFORMATION e INSTALLATION A new saw blade and blade guard are not in the installed condition Assemble as follows CAUTION Always unplug the tool before assembly 1 Installing a new saw blade Uninstall the circular saw blade by loosening the screws holding the blade Always make sure that while dismantling your arms or body is not directly in front of the saw Assemble the new blade making sure that the blade s teeth are pointing down at the tip of the roller table and aligned in the direction of cutting CAUTION Avoid having dust or dirt on the flange as this could provoke slippage of the blade Securely adjust the new saw blade to the assembly with a wrench using a glove if necessary Installing blade guard CAUTION Before installing the blade guard adjust the depth of cut to its maximum elevation Insert the spreader between the blade guard mounting portion stay and the pre
79. forces presented in preceding sections the shafts used were Linear Motion shafts made of AISI 1566 Steel meeting surface finish requirements for the selected linear bearings to travel smoothly 6 2 6 System s Driver An automation machine technology is used to drive the four stepping motors running the vertical and horizontal motion for the Paddle Maker Machine Rockcliff 4 axis CNC motor V10 Driver Figure 21 enabled running the machines at low cost and high performance The 4 stepping motors are Bi Polar motors making the system more powerful A bi polar motor has a single winding per phase unlike a uni polar one which has two windings per phase In a uni polar motor the magnetic pole can be reversed without switching current direction where as in a bi polar one the current needs to be reversed in order to reverse the magnetic field Hence the driving circuit must be more complicated The four colored coded wire connection shown in the schematic diagram in Figure 22 must be carefully checked an incorrect connection will destroy the controller The current level can be adjusted using a potentiometer which converts the voltage to motor output current Stepper motor performance is dependent on the drive circuit The motor drive can handle 30 VDC and can generate voltage and current back into the circuitry Motor failure can occur when exceeding 35 VDC The power source for the driver is a 12 or 24 volt power supply The 24 volt supply will reach
80. forming laboratory located in FIU Mechanical Engineering department The laboratory is a state of the art facility equipped for tribological wear and friction characteristic of Ceramic Metallic Polymer Carbon Nanotube CNT Reinforced Composites and Biomaterials He advised the group first to conduct a literature search on wear resistance and to determine the parameters of interest After doing a literature search the parameters of interest for testing the UHMW PE with the Tribometer were finalized to be 1 All Samples needed be 4 x 1 x 1 The size was chosen to fit in the tribometer tester 2 Only a brief Diamond polish was suggested since material was smooth enough 77 Paddle Maker Machine and Material Selection 3 Normal load during wear 10N It is a moderate load for a soft material when compared to ceramic and metallic 4 Wear distance 300m The distance will give consist data A longer distance will wear more 5 Rotational speed 300 rpm or 250 rpm Considering approximately 0 1 m s The speed is good for polymers were the wear loss is less than that of ceramic and metallic 6 Wear track diameter 6mm Al gt 03 ball Time 50 min 3000sec This will allowed conducting 2 tests for each piece The following properties can be obtained after testing 1 Wear volume 2 Wear Depth 3 Coefficient of friction The Tribometer tester in FIU plasma lab features real time measurement of friction and w
81. his design the holes were going to be drilled by a set of six drill bits mounted in a supporting base and pre set to the desired measurements By having all the drill bits mounted on fixed positions the accuracy of the distances between holes which is the only critical dimension in the complete part is assured This will also improve drilling time since all holes will be drilled simultaneously The drill bits used will be specifically designed for drilling hard and soft plastics and they also feature characteristics such as point and rake angles which minimize or eliminate left overs from the material being removed while cutting the holes resulting in a smoother internal surface More details about this drill bit can be found at Appendix F of this report Some of the concerns with this design are the force required to press all drills at once against the material being drilled and the vibration created by all the drill bits acting on the material simultaneously The six drill bits should be interconnected by a mechanical system and driven by an electric motor mounted in the center of the frame supporting the drill bits and connected to the center chuck The up and down movement will be provided by a stepper motor The two systems 29 Paddle Maker Machine and Material Selection considered were a belt system or a chain and sprocket combination Both of these systems are of considerably higher cost and complexity Hence their construction and assem
82. ials zna edition MeGraw Hill Higher Education Burr Ridge IL 2000 12 Cowie J M G Engineered Material handbook Vol 2 Engineering Plastics ASM International Material park OH 1988 13 Raymond Gauvin Investigating the Thermoform ability of Uhmw Polyethylene Journal of Plastic Film and Sheeting Vol 3 No 4 312 324 1987 14 http www thomasnet com products plastic machinery equipment supplies 5975 1 206 html ThomasNet industrial resource for Plastic Machinery Equipment amp Supplies 103 Paddle Maker Machine and Material Selection 15 http www polysort com linksdirectory machinery aspx PolySort Plastics amp Rubber Machinery amp Equipment industry news and web design tips 16 http www americanplasticscorp com products polyeth html American Plastic Corp 17 http en wikipedia org wiki Ultra high molecular weight polyethylene Wikipedia 18 http www plasticrubbermachines com plastic cutting machine html Plastic and Rubber Machinery Place 19 http www nanovea com Tribometers html Nanovia company 20 http www cisco eagle com systems conveyors Conveyor Safety conveyor safety manual pdf Conveyor safety 21 http www northerntool com downloads manuals 1591806 pdf Blade Safety 22 http www ccohs ca oshanswers safety haz metalworking general html Drill Safety 23 http www machinesafety net na machine safety standards html Machine Shop Safety 24 HARTZMMy Docs EIN33
83. ion is reached namely the first hole e Then go to the Reference All Home section and click on the axis you just moved to the desired initial position e You have just set your starting point for that axis Same process can be repeated for all other axes e Notice that when using this procedure the system of coordinate being used is absolute Example if you need to move the x axis 2 inches to the right then input GO X2 supposing that the position you are moving in from is the zero position Let s say that the actual position shown in the Mach3 CNC Controller under this axis is not zero but x40 and you want to move to the 129 Paddle Maker Machine and Material Selection right 2 inches then you would need to input GO X42 Similarly if moving the z axis 3 inches down from the zero position then inputting GO Z 3 would accomplish that For further details on using G code and M codes click on the bottoms found in left hand corner of the Mach3 interface 130 Paddle Maker Machine and Material Selection Appendix I Linear Stage Specifications SERVO SYSTEMS CO Low Profile Series Miniature Linear Stages Model MLPS 4 10 Description 4 inch travel linear stage with anti backlash lead screw assembly profiled linear rails and two one per rail linear bearings Motor Mount Standard NEMA 23 300 762 mm 250 835 mem DRILL THRU amp CBORE FOR 4 LOCATIONS forms 933 27 0 men sop27 226672
84. le Chip Grind MATS Modified Altemate Top Beve the Other features of the Onsrud ONSRUD product offering include advantage Laser Cut Bodies true running blade for more than just cutting tools accurate cuting ONSRUD CUTTER LP Laser Cut Expansion Slots reduces harmonic 800 Liberty Drive Libertyville 1L60045 USA NR a a Phone 800 234 1560 Fax 847 362 5028 Laser Cut and Polished Bore true centering of the blade to the arbor for optimal performance ar Leitz Metalworking Technology Group 116 Paddle Maker Machine and Material Selection Appendix G Safety Manual Safety Information Manual A DANGER A WARNING AWARNING Climbing sitting Rotating shaft can walking or riding on veyo Exposed moving ts cause severe injury parts can cause severe Injury LOCK OUT POWER Keep hair and before removing loose clothing away KEEP OFF guard WARNING DO NOT START CONVEYOR UNTIL PERSONNEL ARE CLEAR A DANGER ways inspec ar cally w Blac Be Be Careful Avoid Injury IMPORTANT FAILURE TO FOLLOW THESE SAFETY INSTRUCTIONS CAN RESULT IN SEVERE INJURY OF DEATH 117 Paddle Maker Machine and Material Selection GENERAL ONLY TRAINED AND AUTHORIZED PERSONEL MAY OPERATE THE MACHINE PROPER EYE PROTECTION MUST BE WORN BY OPERATOR AND ALL OBSERVERS 1 2 10 11 12 13 No Smoking is permitted Clear Working Area The area around loading and unloading points shall be kep
85. lerated energy of 450KeV Three different N doses The experiment resulted in a change in color of the original white UHMW PE For 5 x 1014 cm density the color changed to orange For 2 5 x 1015 cm ion density the color changed to bright black A study conducted at The Regional Research Laboratory in India was related to sliding wear of PP UHMW PE composition blend 2 UHMW PE was melted and blended with PP in 18 Paddle Maker Machine and Material Selection different proportions A pin on disc tester apparatus was used where the pin was made of polymer sample and the disc was made of EN 24 steel The test was done at different pressures and sliding speeds Parameter and material were e Cylindrical pin size 8 mm diameter and 53mm length e Disc is made of EN 24 steel with hardness of 305Hv e 1 06 6 34 M Pascal pressure e Sliding speed of 0 28 1 09 m s e 300m sliding distance The results showed that the wear volume increases uniformly with applied pressure and sliding distance The parameters used for those studies will serve a guide in selecting parameters that will be needed to compare the current material to the purchased material A ball on disk Tribometer wear tester at FIU Plasma Lab was used 1 3 2 Plastic Cutting Machines Because plastics are thermoplastic processed organic materials with high molecular weight cutting them requires specialized cutting equipment In general a plastic cutting machine must posses
86. limited it will be left for future evaluation Additional information gathered from ETC about the price was that once the radiation doses will be determined by us the cost for production at their facility will be 20 per sheet Since the data obtained with the current ball on disk volume measurements were not as expected and since we concluded that this test is inappropriate for the polymer in use three approaches to measure the depth of the tracks were considered as well as one different test method l The three samples tested using the tribometer were cut vertically across the tracks using a diamond cutter and the depth of the track was measured using an optical comparator Those tools are available in AMRI lab in FIU However the high speed diamond saw was out of order so this method was not an option 2 The Profiliometer tester located in AMRI lab Figure 45 was used to measure surface roughness Using the Stylus 12 5 u curved tip contact to measure surface roughness 89 Paddle Maker Machine and Material Selection Figure 45 Profiliometer Parameters input e 2000 u m 2 mm length of scan e 0 2 samples per u e 8sec Output e A average between upper and lower surface Figure 45 Figure 46 Average Delta Surface Roughness Results There were inconsistent results measuring the same track This relates to the fact that the assumption is that the roughness outside the groove is at the same level The stylus is a technique
87. mine how much the different parts of the machine displace when under stress and the results are presented in the following 5 7 1 Stress Analysis Model name Assem5 Study name Study 1 Plot type Static nodal stress Stress1 Deformation scale 19417 4 von Mises N m 2 7 107e 005 6 515e 005 5 823e 005 5 330e 005 4 738e 005 4 1468 005 3 554e 005 2 962e 005 2 369e 005 1 777e8 005 1 185e 005 5 928e 004 5 840e 001 52 Paddle Maker Machine and Material Selection 5 7 2 Strain analysis Model name Assem5 Study name Study 1 Plot type Static strain Strain Deformation scale 19417 4 ESTRN 2 590e 006 2 375e 006 2 159e 006 1 844e 006 1 728e 006 1 512e 006 1 287e 006 1 081e 006 8 654e 007 6 498e 007 4 342e 007 2 185e 007 2 920e 009 5 7 3 Displacement Model name Assem5 Study name Study 1 Plot type Static displacement Displacement1 Deformation scale 19417 4 URES m 5 319e 006 5 793e 006 5 256e 006 4 739e 006 4 213e 006 3 686e 006 3 160e 006 2 633e 006 2 106e 006 1 580e 006 1 053e 006 5 266e 007 1 000e 033 53 Paddle Maker Machine and Material Selection 5 7 4 Factor of Safety analysis Model name Assem5 Study name Study 1 Plot type Design Check Design Check1 Criterion Max von Mises Stress Factor of safety distribution Min FOS 5 7e 002 FOS 1 000e 000 9 167e 001 8 333e 001 7 500e 001 6 667e 001 5 833e 001 5 000e 001 4 167e 001 3 333e 001 2 500e 001
88. n 50 0 Ib in at 20 0 in MAXIMUM SHEAR FORCE 5 01b from 0 0in to 20 0 in 5 0 lb from 20 0in to 40 0 in MAXIMUM STRESS Tensile 4074 366 Ib in No Limit specified Compressive 4074 366 Ib in No Limit specified Shear Avg 2 25 4648 Ib in No Limit specified ANALYSIS AT SPECIFIED LOCATIONS Location 20 0in Deflection 0 03746543 in 0 00000000000000008 deg Moment 50 0 Ib in Shear force 5 0 Ib Tensile 4074 366 Ib in Compressive 4074 366 Ib in Shear stress 25 4648 Ib in Slope 134 Paddle Maker Machine and Material Selection Appendix L Drill Motor Options Company Bodine Electric Company amp BODINE 34R Series AC Induction Motor Model 0295 Specifications COMPANY Model Number 0295 Category Three Phase Non Synchronous Speed rpm 1700 Rated Torque oz in 119 Motor HP 1 5 Voltage 230 Hz 60 Phases 3 Amps 1 2 Radial Load Ibs 50 Length XH inch 6 69 MODELS IN THIS SERIES Weight lbs 9 gt 0290 Connection Diagram 074 10102 gt 0291 Capacitor Part Number This model does not require a capacitor gt 0293 Product Type 34R6BFPP q294 gt 0295 0296 gt 0299 gt N0297 COPYRIGHT 2010 BODINE ELECTRIC COMPANY Company Sinotech 140 Watt 100mm AC Gear motors 5120 am 104104 187 224 206 135 Paddle Maker Machine and Material Selection Characteristics of Motors Used In Gearmotors Model Mot
89. n a Drag A Flight Conveyor These paddles needs to be 3714 long 2 thick and 134 wide having six holes 7 16 in diameter each spaced by a distance of 512 The current design of the paddle also features an angle cut in one of the sides to decrease friction A machine The Paddle Maker was constructed to produce the paddles autonomously from a given sheet of raw material Thus the machine first moves the sheet of raw material to the position where a pulley belt system driving the drill bits makes the holes Then a saw moves by means of a stepper motor and takes care of the cutting 6 2 Parts List 6 2 1 Motors and Stepping Motors Four Nema 23 Hybrid Bipolar Stepper Motors of 270 oz in 1 4 dual shafts were used to move the different linear mechanisms Typically controlled by a computer and driver these motor are among the most common systems used in machines requiring motion control Advancements in electronic controls have made steppers motors more popular than ever in almost every modern industry The torque of these motors greatly exceeds that required by the system the reason for this is that these motors were bought in a complete kit including the power supply and 56 Paddle Maker Machine and Material Selection controller By having all stepper motors of the same size and frame will facilitate future maintenance 6 2 2 Gears and Timer Belt The design of the machine reguired means transmitting power from the electric mo
90. n this technology Table 3 Paddle Production Cost Interstate Plastic com 1 2 x 37 x72 205 714 Rplastics com 1 2 x 37 x120 342 857 The Gund Company 1 2 x 37 x72 205 714 Current Price Below a discussion of the equations used to produce this table is presented e Time minutes 5 min sheet size paddle size e Machine functioning cost Power hours to produce paddles 0 10 per KW h e Cost of 1 paddle sheet cost machine functioning cost amount of paddles produced from that sheet In the time equation five minutes is the time empirically determined required to manufacture a single paddle That multiplied by the amount of paddles obtained from each sheet gives you the time that it takes to make paddles out of that sheet The Paddle Maker uses 2 DC motors and 4 stepper motors that account for the total horsepower of the machinery to be approximately 1 HP This is converted to KW and then to KW h using the time calculated in the first step That value times the average KW per hour cost in Florida namely 0 10 yields the machine functioning cost 55 Paddle Maker Machine and Material Selection In order to obtain the amount of paddles produced from a given sheet the size of the sheet is divided by the desired paddle size 6 Prototype Construction 6 1 Description of Prototype The target of this project was to build a machine that would produce construction paddles to be fitted i
91. ncluding 1 When the blade is pinched by an internal stress in the work piece 2 The work piece moves up or sideways during a cut 3 The material is pinched between the rear of the blade and the fence 4 Underpowered saw It is very important to minimize the potential saw blade injuries occurring This can be done by applying the safety rules when working with such a machine The Paddle maker machine includes an automated drilling operation run by step motors and using a drill bit The drilling operation will allow us to drill a defined hole into or through an UHMW PE work piece in a very repeatable manner However power drills can cause severe injuries According to U S Consumer Product Safety Commission data for year 2003 approximately 4 100 people received hospital treatment for power drill related injuries A video named E 061Saws Grinder Drill Press Instruction is available from the ANR Environmental Health and Safety Library at http safety ucanr org To avoid accidents the 99 Paddle Maker Machine and Material Selection operational safety rules attached in Appendix G must be observed and understood by everyone working on the Paddle Maker Machine 9 Conclusions The main objectives of this project were to design and construct a prototype of a machine that will manufacture paddles for a specified application and to explore the properties of the material being used to manufacture these paddles in the search for
92. ncy for the system was calculated to be 1 009 rad sec gt All motors frequency was obtained by converting RPM to Rad sec The smallest natural frequency for the drilling stepper motor calculated to be 5 236 rad sec gt Since system S different than any O any motor and since the value does not fall within 10 of any motor s frequency value the machine should have no resonance 5 6 Deflection Analysis Member deflection is a considerably important topic in the design of any structure Even though the system here presented consists of a combination of simple structures determining the deflection of the key parts of the machine was of interest The linear shafts holding the drilling assembly being the thinnest and longer members were the components where the major deflection was expected The deflection and other properties of interest for these supporting shafts were calculated using the very well known software Beam 2D version 3 1 and are presented in Appendix K The two tentative dimensions for these shafts were 3 8 and 1 2 The load carried by two of these shafts at any time is 8 lbs 50 Paddle Maker Machine and Material Selection but to be on the safe side a 10 Ibs load located at the center was simulated on a single shaft After performing this analysis the shaft was picked based on minimum deflection specification The maximum deflection was found to be 0 03746543 at the center of the shaft where the load was being
93. nd Company Inc ELECTRICAL INSULATION MATERIALS St Louis Missouri USA INSULATING COMPONENTS FOR TEL 314 423 5200 POWER SYSTEMS EQUIPMENT FAX 314 423 9009 MATERIAL DATA SHEET Item UHMW PE Key Characteristics Test Method Units English SI Typical Values Specific Gravity 73F ASTM D792 0 94 Tensile Strength 73F SE ASTM D638 psi 5500 Tensile Modulus of Elasticity mt m ASTM D638 psi 116 000 Flexural Strength 73F ASTM D790 psi 3 600 Flexural Modulus of Elasticity 73F ASTM D790 3 psi d 116 000 Compress ive Strength 10 10 Deform nation 73F TF ASTM D695 u psi cg rae 3300 Compressive Modulus of f Elasticity 73F ASTM D695 psi 100 000 Hardness Durometer Shore D Scale 73F ASTM D2240 66 68 IZOD Impact Strength Notched 73F ASTM D256 Te NC ft lb in s No Break Coefficient of Friction Dry ya Steel Dynamic QTM 55007 ia rs 0 15 p Heat Deflection Temperature 5 264 per ASTM D648 m 116 Continuous Service Temperature i in Air P Max omg F Muse 180 re Dielectric Strength Short Term HASIM D149 Volts mil n a Surface Resistivity ASTM D257 Obinsisquaie X 2105 RAE Flammability 3 1 mm iei in ULA 5 DE HB HIS Water Absorption Immersion 2 24 s ASTM D570 by weight i lt 0 01 Water Absorption nesen Saturation ASTM D570 Yo by weight 0 01 EC l Data represents estimat
94. nd distribution services as well as services in sand gravel and crushed stone retailing Being the biggest producer of construction aggregates and a top producer of cement in Florida there is no room for inefficiencies or delays in such a busy operation That s why the company is interested in a feasible improvement or solution to this ongoing issue at a cost effective price Vulcan operates a Drag a Flight Conveyor in their Miami Quarry facility that uses polyethylene paddles as a way of transporting the cement powder from the rail cars to the trucks It usually takes twenty minutes to load a truck with cement powder when the paddles are new however when they are worn out loading time could take up to one hour and twenty minutes Furthermore orders of these construction paddles sometimes get back stocked and subsequently the operation gets delayed due to the inefficiency of the machine To make matters even worse these paddles cost 13 dollars apiece and the conveyor requires 114 of them in order to function properly It takes about 2 months for the paddles to completely wear out However if a more cost 14 Paddle Maker Machine and Material Selection effective material or a more friction resistant material were to be used for this application efficiency and productivity of the machine could dramatically improve Moreover if Vulcan Materials Company were able to produce these paddles independently the company would not need to buy th
95. ndergraduate Program Director for the Department of Mechanical and Materials Engineering at Florida International University Dr Bao and Dr Tsukanov for their advice on Solidworks Dr Levy for his guidance in the Vibrations Analysis Professor Richard Zicarelli Coordinator for Engineering Manufacturing in Florida International University Dr Agarwal and his Staff Department of Mechanical and Material engineering in Florida International University Professor Neal Ricks and his staff Nanofabrication Lab Manager for guidance on material testing Mr Clemente Dieguez owner of Grainman Corporation Mr Alan Arch owner of Southern Gear Inc for tour All fellow engineers that at one point or another help us and or commented on the work being done Paddle Maker Machine and Material Selection Table of Contents Ethics Statement and Signatures sssssseeeeeeeeeeeeee 2 Acknovledements AE 3 BAS gogdll Mee sste reS sons sis 8 List of ucl 10 Nomenclature m M 11 ADA Ca 12 1 Introduction sssseesseseseeeeesoeeeeseseneeesoeeeeseso 13 Led Problem State ii aki 13 12 MO IA IA ia 14 1 3 Liter
96. ne A review is conducted here on the brainstorming and information gathering that lead to the development of such machines over time 15 Paddle Maker Machine and Material Selection 1 3 1 Material UHMW PE has become the material of choice in hip and knee joint prostheses in human body In addition it is used in many industries where moving and conveying materials presents challenge of finding solution to abrasion sticking and wear It is the answer in applications such as drag flights and paddles side rails and skirt boards When compared to other polymers UHMW PE possesses superior mechanical toughness and wear resistance Despite the success in surgical applications implanted components produce wear debris and it is necessary to repeat the surgery and revise the prosthesis In the case of the Drag Flights application UHMW PE paddles wear out quickly after being constantly rubbed against the steel counter face Cross linking of UHMW PE has been shown to improve its wear resistance by 70 when compared to conventional material Cross linking changes the chemical characteristics of the material It alters the bond between molecular chains reduces crystalline processes alters the free radical content of the material and influences the surface properties significantly Many experimental tests were done trying to understand the wear behavior and wear debris distribution of UHMW PE when rubbed against other material A literature survey of
97. nsure it is a new idea one must search the US sometimes foreign patents and technical journals for related inventions One tool usually used by lawyers when they want to research whether an invention is original or not is google com patents A US patent cost depends on the technology involved 40 Paddle Maker Machine and Material Selection The initial cost to have a patent searched and to have an opinion if the idea is patentable is 650 to 1000 A patent application which includes 2 3 drawings costs 150 per one drawing for a total of 450 Nezt an abstract and detailed description has to be prepared for the application The fees in simple mechanical cases are 4500 The fees for software computers and electrical systems are 7000 For a more complez system such as shock absorbing prostatic device the cost is 15 000 For highly complex such as telecommunication networking system the fee would be 15 000 Next the application filing fee costing 355 An amendment for the application can cost up to 2000 in attorney fees Final patent issue to the USPTO costs is up to 1300 Maintenance fees range 2995 5790 and it increases over the life of the patent The patent process is relatively expensive An inventor can spend up to 10 000 in order to obtain a US patent An additional fee of 20 000 for a patent protection in a foreign country can be expected Moreover it takes about 36 months for the complete process A search
98. nt 3 4 1 Design Alternative 1 Roller Table Since early in the conception of this project it was realized that some sort of mechanism to move the UHMW PE sheet from point A to B while controlling the rate of movement as required One approach to solving this issue was to build a roller table as seen in the picture below This design includes nine galvanized steel rollers purposely separated at different distances to minimize the torque required to move the work piece forward A stepper motor was selected that would easily overcome this torque and both the legs and frame were made of standard 1 x 2 steel tubing 3l Paddle Maker Machine and Material Selection Figure 9 Roller Table Design Alternative 3 4 2 Design Alternative 2 Automatic Material Handling Table The table illustrated below was one of the alternatives discussed while brainstorming on how to move the sheet of material to the specified position where the other processes were going to be conducted The way this works is having two sliders one long the x axis through which a pusher slides and another on the side that holds the sheet of polyethylene and moves with it at the same rate the pusher displaces the sheet forward Both of these mechanisms are moved by stepper motors turning two lead screws They lay in an aluminum table to provide system stability and accuracy One of the biggest disadvantages of this design is that it requires a lot of machining to bring this mo
99. or an improved wear resistance ultra high molecular weight polyethylene sheet was conducted The Gund Company is the current paddle supplier for RBT It is also the current vendor for the new and improved purchased material A UHMW PE sample with crosslink process was obtained from the Horn Plastic Inc Those three different materials were tested and their wear resistance properties compared Material Three physical properties for three different samples Figure 41 were compared Tensile Strength Modulus of Elasticity and Hardness The current UHMW PE used by RBT Company obtained from the Gund Company Physical Properties are Tensile Strength 2 500 PSI Modulus of Elasticity in tension 1 02 x 10 PSI Rockwell Hardness R38 A purchased improved UHMW PE from the Gund Company Physical Properties are Tensile Strength 5 500 PSI 80 Paddle Maker Machine and Material Selection Modulus of Elasticity in tension 116 x 10 PSI Hardness Durometer shore D scale 68 A purchased crosslink UHMW PE sample from the Horn Plastic Inc Physical properties are unknown Color is Orange Procedure 1 Two pieces of each material were cut to length of 5 x 1 x 1 2 Samples were diamond polished for a very short time This was done in FIU AMRI Lab 3 A Tribometer Tester Figure 39 and 40 located in FIU plasma lab was use to test and compare wear resistance 4 Test parameters e Normal load during
100. or with gear Motor shaft 6IK140GU AF 61K140A AF gear motor gear induction motor motor 6IK140GU CF 6IK140A CF gear motor gear 140 induction motor motor 61K140GU SF 6IK140A SF gear motor gear 140 induction motor motor 6IK140GU S3F 6IK140A S3F gear motor gear 140 induction motor motor 61K140A DF 140 induction motor 6IK140A TF 140 induction motor 61K140A T3F 140 induction motor The required capacitor value will vary depending on operating voltage A correct capacitor is required to match the applied voltage o O z 5 Volt Ja 1ph110 1ph220 3ph220 3ph380 1ph220 3ph220 3ph380 KJE El Le f PR TT Freq Hz 50 50 50 50 50 50 50 Rated Start Capaci Spd Curr Torq torq tance 2 4 CONT 1350 2 00 0 99 0 90 30 0 250 CONT 1350 1 13 0 99 0 90 10 0 450 CONT 1350 0 95 0 99 3 50 CONT 1350 0 55 0 99 3 50 CONT 2800 0 88 0 45 0 44 10 0 450 CONT 2800 1 25 0 48 3 33 CONT 2800 0 42 0 48 3 33 General Motor Characteristics Insulation Resistance 100MO at 500V between motor winding and shell Insulation Voltage 1500V 50 60Hz imin between motor winding and shell Temperature Rise Max 80 C Insulation Class Class B 130 C 136 Paddle Maker Machine and Material Selection Operating Temperature 10 C to 40 C Three phase 10 C to 50 C Humidity 85 ma
101. p to be about 910 hours total which multiplied by 20 per hour yields around 18 200 of prototype development cost The 20 per hour rate was used in these calculations since this is the average rate per hour charged by machine shops in Miami and is also around the average salary for in training engineers such as ourselves However of this time 208 hours were devoted to machining the different components had the team contracted the services of Mr Zicarelli at the FIU s manufacturing center this time would have been decreased to about 55 hours which would have cost about 1375 If this prototype were to be mass produced then this price would be significantly reduced 68 Paddle Maker Machine and Material Selection The following graph shows the approximate amount of hours that each member worked per week throughout the duration of these last two semesters The peak represents the spring break week where the team spent about 250 hours building the prototype The total amount of hours is as follow Orena 389 hours Jorge 393 hours Nestor 396 hours Hours per week 70 60 50 40 30 20 10 Project Hours 10 15 20 25 30 it Weeks Orena te Jorge E Nestor Figure 31 Paddle Maker Team s Total Hours 69 Paddle Maker Machine and Material Selection 7 Testing and Evaluation 7 1 Design of Ezperiments 7 1 1 Mack 3 CNC controller Input Verification Using Mach3 software r
102. prototype moving by the same system as the saw could do the side angle Step 4 Evaluation of the process was performed on the accuracy of the design Step 5 Improvements were done until the final product was obtained successfully 3 7 Proposed Machine Design After considering all of the above mentioned systems and procedures the final conclusions were e The design preference for drilling was Design Alternative 2 Drilling Workstation e The design preference for material movement was Design Alternative 1 Roller Table e The design preference for cutting was Design Alternative 3 Circular Saw Workstation The complete design included a table with rollers that facilitated the movement of the sheet toward the drilling station This table consists of several free motion rollers and one driver roller that pulls the raw sheet forward by a prescribed distance which is the desired width of the paddle Then the drilling system moves through linear stages in the horizontal and vertical directions to make the six holes needed 38 Paddle Maker Machine and Material Selection 4 Project Management 4 1 Timeline Tasks 09 05 09 09 12 09 09 19 09 09 26 09 10 03 09 10 10 09 10 17 09 10 24 09 10 31 09 11 07 09 11 14 09 11 21 09 11 28 09 12 05 09 12 12 09 12 19 09 12 26 09 01 02 10 01 09 10 01 16 10 01 23 10 01 30 10 02 06 10 02 18 10 02 20 10 02 27 10 08 06 10 03 13 10 03 20 10 03 27 10 04 03 10 04 14
103. r that will be studied carefully since a wider 27 Paddle Maker Machine and Material Selection cut means more wasted material The cutting blade will travel along the complete width of the plastic sheet powered by an electric motor that will rotate in both directions moving the blade back and forth Figure 5 Circular Saw Workstation Design Alternative The angle in the scraping corner of the paddle was going to be cut by a corner round router Figure 6 powered by a motor turning it and is to be installed in an assembly together with the saw which in turn will be moved by a stepper motor The installation of the router and the powering motor are not done in the current prototype but will be integrated in the machine in the near future Figure 6 Round Corner Router 28 Paddle Maker Machine and Material Selection Feed rate for all components were analyzed theoretically and then tested physically particularly those of the cutting tools to assure that the material did not burn in the process damaging the tools or the machine 3 3 Drilling 3 3 1 Design Alternative 1 Mechanical Drilling Assembly Another approach for our machine was to build a straightforward combination of mechanical components equipped with electrical controls This design is depicted in Figure 7 As raw material will be obtained in the form of sheets cut to the required width the cutting performed by the machine will be along the width of the sheet In t
104. reason we re showing both is that they serve as a comparison between the two main design alternatives As can be seen by using the drilling workstation choice a sum of around 400 would be saved This ended up being an important factor on the decision of choosing the final design The Paddle Maker Table 5 Final Design Cost Description KtemPrice Qty Subtotal Chus 00 Roundrods 000 WeldingRods 000 3 8 by 24 Shaft Bots 0 00 Tol JJ 196434 67 Paddle Maker Machine and Material Selection Table 6 Initial Design Cost Stepper Motor 80 00 250 00 00 3 240 00 00 3 75000 PowerSupply 200 00 1 200 00 Wiresandcrimps 5000 1 5000 Drillits 2500 7 S16100 Chuks 1500 7 10500 Roundrods 3000 4 120 00 Tubing 2284 1 2284 WeldingRods 1000 1 1000 41 2 Circular Saw Blade 25 00 1 2500 3 8 Corner round router 2995 1 29 95 Vbeits 20 00 8 16000 Bolts 5 00 1 15 00 Bearings 2000 14 280 00 PolyethyleneSheet 278 00 1 278 00 Tot 8244679 Not included in these tables is the labor cost involved in this project After having Description ltemPrice Qty Subtotal 3 3 1 1 7 7 4 1 1 1 1 1 14 1 finished our project all hours related to design construction and testing added u
105. resresressessresresstssrssrenseeeresreesteseseresee 54 5 8 Cost Analysis for One Paddle age dd 54 6 Prototype Construction sssssssssssocssoocsooesossccoessooosssoscosscoossososssocssosecosssosessseesssoscsssessssssesssso 56 bl Des ription of PIMA wA ose pre ipe iseseisana 56 OPL 56 6 2 1 Motors and Stepping Motors sasessemsmendsensenmn ennnmegvmami 56 562 2 Gears aud Timer Belt ease 57 6 23 BEANE PEN 57 EE EEE in eseiski idake ses iosia 57 5625 Rods and ipi 58 6 2 0 Systemi S DVT cieee m MAPEMA TA UWAKI vastes daemons 58 Paddle Maker Machine and Material Selection 0 2 7 SYSTEM S SON ae 60 62 5 SAW Assembly ii Ea Esa ERE E E 61 0 2 9 D JR ER 62 6 2 10 Roller Tables eee 64 6 3 AU AA E a uiae 64 6 4 Prototype Cost NN ENG 67 7 Testing and Evaluation e 70 Tol Design of Ee EAI I osi qa desea to deste aerem ive ies re aoa EEEE E EEEE EES 70 7 1 1 Mack 3 CNC controller Input Verification lt w wwmmmemmmnmmmamanm nima 70 MN GE Up EE T E O AG edie 73 7 1 3 Plan and Recommendation for Material Testing eese 77 LIA TE Testing cT 78 PTR 80 7 2 1 Paddle Material Comparison aine cento rea a raten poe accees eruere a Re bean kutta 80 7 2 2 Paddle Maker beef onde 84 7 3 Evaluation of Experimental Results c2ccccsssisscaseceesonsecccssonsvecenstonestessecesveesatesssensueseanees 84 731 Material sagaene 84 7 4 Imp
106. rk piece firmly with the table and the rip fence or miter gauge Do not bend or twist it while feeding If the work piece is bent or twisted dangerous kickbacks may occur 123 Paddle Maker Machine and Material Selection NEVER withdraw the work piece while the blade is running If you must withdraw the work piece before completing a cut first switch the tool off while holding the work piece firmly Wait until the blade has come to a complete stop before withdrawing the work piece Failure to do so may cause dangerous kickbacks NEVER remove cut off material while the blade is running NEVER place your hands or fingers in the path of the saw blade Be especially careful with bevel cuts Always secure the rip fence firmly or dangerous kickbacks may occur Always use work helpers such as push sticks and push blocks when cutting small or narrow work pieces or when the dado head is hidden from view while cutting Work helpers Push sticks push blocks or auxiliary fence are types of work helpers Use them to make safe sure cuts without the need for the operator to contact the blade with any part of the body OPERATION CAUTION NEVER remove cut off material while the blade is running NEVER place your hands or fingers in the path of the saw blade Be especially careful with bevel cuts NEVER stand or permit anyone else to stand in line with the path of the saw blade Read the Manual Read all warning labels and the own
107. rovement of the Design RR m 88 7 4 1 Material Wear RESiSlAneG magnemamietmnmemienumiikemtlandtavian 88 7 4 2 Overall Machine Components and Design eee 94 8 Design Considerations Pec 95 S l Assembly and Disassembly waa 95 8 2 Safety and Maintenance PFOCBOUEe s reino ti ipee ipsom Iqbeni deci oes reas dla ind nas 95 8 3 Environmental Impact M 96 TEN RN TOP cm 97 Engl m 100 10 Future fig C T 102 11 oiu ie e 103 1 Ads 106 Appendix A Paddle Material Data She t usmemmemmmsssvmniprsssisrssoemdurbaneaksntemnnkanedee 106 Appendix B Data Sheets From Different Vendors eee 109 Appendix C New vs Damaged Paddle 1 pntat rtt tai e tesa Feste aane 111 Appendix D RBT Drag A Flight Conveyor eese 112 Appendix E Water Jet Machining Illustration eese 113 6 Paddle Maker Machine and Material Selection Appendix F Drill Bit and Saw Blade Description eene 114 Appendix G Safety Manual ede ttu step enden ette ten ped mme dust 117 Appendix H Paddle Maker s User Manual ueoseepseteeo tristis eR pane ae vos 127 Appendix I Linear Stage Specifications rnooornvvonnvovnvnnevvvrnovnnnvnvnvnnnnnnnnvnnnvevnvnnennneneennnne 131 Appendix J T rques Calculation nieto iare iod erts Gore po e
108. s 7 4 Improvement of the Design 7 4 1 Material Wear Resistance The results shown in Section 7 2 and 7 3 prove that a search for a better wear resistance material and a use of a different kind of test must be followed up It is clear from the literature survey and many studies done on that subject that cross linked process on UHMW PE can improve wear resistance The cross linked sample tested in this experiment was shipped to us at no cost and did not have any data sheet available We contacted Electron Technologies Corporation ETC a 47 year irradiation processing provider in New England to ask their 88 Paddle Maker Machine and Material Selection expertise on how to improve wear resistance for UHMW PE The information gathered made clear that research and development for different radiation doses on different samples must be obtained and tested In general irradiation can improve the physical properties of cross link bi section or can degrade and make it brittle Hence depending on the level of the cross linking will give different physical properties Radiation will increase the melting temperature and will make it more solvent resistance and a better heat resistant In ETC R amp D facility they will apply three different radiation doses of 2 5MR 5MR and 7 5MR Testing of those samples will determine which doses improve wear volume and COF However the cost for one hour lab in R amp D at their facility is 400 Since the budget is
109. s conducted so that the team could have an understanding of similar machinery already on the market Further detailed explanation on motor selection is included in Section 6 of this report and in Appendix J Torque Calculations 23 Paddle Maker Machine and Material Selection 2 2 2 Drilling Control The paddle design currently being used in the RBT conveyors features seven 7 16 holes spaced at 5 however Nestor has noticed that while replacing old paddles with new ones that the middle hole is located where the paddles break most of the time Therefore we are going to avoid making this middle hole in order to make the paddle s design more lasting and stable This will also reduce drilling time and therefore the cost of producing one paddle Based on this specification the drill bit was selected and the G code program written to instruct the Mach 3 how to move the stepper motors The fabrication of the finished product was influenced heavily by the way the three different processes operate simultaneously namely first the roller table then the drilling operation then the cutting finally the roller table moves the thickness of the paddles and the whole cycle starts over 2 2 3 Movement Control The Paddle Maker machine has three main moving parts the roller table the drilling station and the saw station Specifications for the roller table were to move a sheet of UHMW PE of 3714 by 38 by 4 weighing about 40 Ibs Based on these siz
110. s discs volume data is more accurate In addition with the ball on disk method local temperature causes the material to melt and deform Melting can increase the contact area of the ball and this causes the friction force to increase This might be the explanation for the uneven roughness surface depicts in Figure 47 when using the Profiliometer 93 Paddle Maker Machine and Material Selection 7 4 2 Overall Machine Components and Design In the current design simple threaded rods are used to aid the drilling and sawing stations to move in the horizontal direction In order to improve the travel distance and speed of the assemblies a precision lead screw from Grainger catalog Appendix P with inch travel pitch will have to be purchased The cost for two lead screws one for the drill and one for the saw is 320 The maximum speed for the stepper motor in the current design is 950 RPM Each assembly has to travel a horizontal distance of approximately 45 If a new lead screw of 1 pitch is purchased it will take 2 84 sec for the saw and drill to travel the 45 Figure 49 shows comparable calculations for the time it takes when the lead screw comes with 1 and 2 travel distance per revolution For 1 inch travel per revolution 950 RPM _ 950 inch ii 45 inch 60 sec i 60 sec X gt X 2 84 sec For 1 2 inch travel per revolution 950 inch B X 1 gt X 475 inch 3 inch 475 inch ii 45 inch 60 sec i X
111. s the following features High level of precision Good edge quality Energy efficient Low maintenance requirements Facility of cutting virtually any shape 19 Paddle Maker Machine and Material Selection However since the design of the Paddle Maker machine is intended for a very specialized function only a few tasks are of key importance to the design and development of our paddle maker Among these tasks are Ability to move a sheet of the chosen material to the section where holes are to be made e Six 7 16 equally spaced holes are to be drilled The machine must be energy efficient It must have low maintenance requirements and be autonomous The current manufacturer of these paddles uses a water jet cutter to produce them A water jet cutter is a device that enables cutting materials like metals and plastics by means of a high speed and pressure water jet or a mix of water and an abrasive substance The process is very similar to that of water erosion yet significantly accelerated and concentrated It is usually implemented in manufacturing and industrial plants especially when the material that needs to be cut is sensitive to high temperatures It is suitable for various kinds of materials such as heat sensitive delicate and hard ones Water jet cutting is used for operations such as cutting shaping carving and reaming Rubber foam plastics composites stone tile metals food paper are just some of
112. sheet of raw material slides towards the cutting machine As mentioned above these are some of the most essential components included in the assembly of the present machine as improvements are made more components will be required 5 4 Force Analysis The force analysis is mostly covered in Appendix J Torque Calculations section Here the torque needed for the two main stages of the machine was analyzed namely the linear stage and the roller table The torque for the roller table stepper motor was found to be approximately 0 23 Newton per meter Nm or 32 7 ounces per inch OPI while the torque that the stepper motor on the linear stage would need to exert was found to be around 17 7 ounces per inch OPI for the worst case scenario which is when the drilling assembly is going up this torque is called raising Torque or Tr All assumed values specified in Appendix J were those of worst case scenarios taken from mentioned sources In the case of the circular saw motor the drilling motor and the stepper motors providing the horizontal movement for the drilling assembly finding the necessary torque was accomplished as follows 46 Paddle Maker Machine and Material Selection First we looked at different similar saws in the market and found that the best one to compare to was a cordless one since we are going to use a DC motor to power the saw Usually cordless saws range around 1 20 horse power HP and have a torque of about 7 5 OPI
113. ssure plate Tighten the hex bolts A with the offset wrench The spreader installing location is factory adjusted so that the blade and spreader will be in a straight line However if they are not in a straight line loosen the hex bolts B and adjust the blade guard mounting portion stay so that the spreader is aligned directly behind the blade Then tighten the hex bolts B to secure the stay CAUTION Always grasp the striped portion of the offset wrench when tightening the hex bolts If you tighten the hex bolts while grasping the offset wrench further than the striped portion the hex bolts may be damaged and or an injury to your hand may result If the blade and spreader are not aligned properly a dangerous pinching condition may result during operation Make sure they are properly aligned You could suffer serious personal injury while using the tool without a properly aligned spreader 122 Paddle Maker Machine and Material Selection NEVER make any adjustments while tool is running Disconnect the tool before making any adjustments There must be a clearance of about 4 5 mm 5 32 13 64 between the spreader and the blade teeth Adjust the spreader accordingly and tighten the hex bolts A securely Attach the table insert on the table then check to see that the blade guard works smoothly before cutting 2 Adjusting depth of cut The depth of cut may be adjusted by turning the handle Turn the handle clockwise to rais
114. sured average difference of 18 between upper and lower surface Results 92 Paddle Maker Machine and Material Selection Smaller numbers mean the groove is less deep and therefore less volume loss With the Optical Magnification Microscope the new samples exhibit smaller volume loss just the opposite of the results that were obtained by calculation the volume loss using the tribometer Appendix M lab notes 4 A Pin on Disk test mentioned in the literary survey is being considered as an alternative to the Ball on Disk test Here the Pin is made of UHMW PE and the Disk is made of Aluminum Oxide Ceramic abrasive material The weight loss will be measured in the same manner as in the Ball on Disk test where the pin and not the disk is weighted The Optical Magnification Microscope depicts that the new samples has the smallest volume loss and not the old sample After using the optical microscope one can conclude that with a groove making technique ball on disk there is a wide range of results between the same sample comparing the two tracks and between the old and new material In the tribometer tester a load is applied on the sample and after taking out the load there is an elastic recovery of the material The ball is forced to go down while measuring the depth but after the test is done the ductile material relaxes and deforms back That makes the LVDT less accurate and therefore unreliable When using metal and ceramic material a
115. t clear of obstructions which could endanger personnel Machine Service Service machine with only authorized maintenance personnel Eye Protection Approved eye protection must be worn at all times in the shop area Wear Proper Apparel Appropriate clothing is required while operating the machine It is prohibited to wear shorts and open toed shows Wear protective hair covering to contain long hair to prevent becoming entangled in the machines Do not wear gloves do not hold rag while operating machinery They can be easily caught in the machines that are in motion pulling the operator into the equipment Keep Hand Clear of Moving Parts Hands are to be kept clear of moving parts while equipment is in motion Machines must be completely stopped before handling moving parts or the work piece Keep Guards in Place The safety guards are to be kept in place at all times unless the shop supervisor gives you permission to remove them Prevent Slippage Spill fluid or cutting material found around work area must be clean immediately to prevent slipping and injury Care of Hazardous Material Only approved chemicals will be used All hazardous materials and their disposal must meet OSHA requirements Contact the Environmental Safety Office for disposal of all chemicals Turn Power Off Never leave tools running unattended Turn power off Turn the Motor Switch Off and unplug from the power source when not in operation Reduce the Risk of Unint
116. t higher friction causing an increase in the curve Next the average data points of the first minute after steady state starts were subtracted from the last minute the 50 minute L Io nN V A L 2 A T R 2 r R h R n sin1 gt R f L r R h R R h k W Figure 44 Volume Loss Formulas Where V is wear volume loss A is the area of sector minus triangle R is the radius of Alumina ball r is the radius of wear track h is the average depth obtained from software data points L is the track length n is the angle of the arc sector 85 Paddle Maker Machine and Material Selection Weight loss the data shown on the lab notes in Appendix N obtained using a scale before and after each track The scale measured in micro grams 0 0001 Coefficient of Friction Figure 43 obtained from the Excel data sheet Results COF Results New sample e Upto the first 50 meters Figure 43 the values are the lowest for both tracks when compare to the other samples e The values increased much higher for the second track only after the first 50 minutes Orange sample e The values are the highest of both tracks Old sample e Trend is similar for both tracks The average COF is similar in value e For the first 50 meters the values are higher than those of the new sample Weight Loss Results e The data shown similar weight loss for both new and old samples e There is an increas
117. t in severe injury or death OSHA 25 code violations must be followed Also it is mentioned that only authorized trained personal should operate the machine The manual is divided into four sections e The 1 section is general machine shop safety information e The 2 section includes conveyor safety information operation and maintenance 95 Paddle Maker Machine and Material Selection e The 3 section contains table saw safety information operation and maintenance e The 4 section includes drilling safety information operation and maintenance In addition the safety manual includes all warning and hazards signs to be displayed in the shop to assure personal awareness 8 3 Environmental Impact An assessment of the possible environmental impact of chemical or hazardous materials being used must be taken into account while constructing a machine The impact can have positive or negative social and economical aspects Grease will be used to lubricate the machines components In addition drilling holes through plastic sheets and the scraping corners of the paddles will create a great deal of chips It is our responsibility as engineers to promote a clean environment by recycling the chips and ensuring the use of non hazardous lubricants that will not cause severe health problems EP 2 lubricating grease will be used to lubricate the components The machine will need to be lubricated every 250 operational hours It is a petroleum
118. terial Selection Electric Drill Safety SAFETY INFORMATION e INSTALLATION 1 Ensure that the drill machine has a start stop button within easy reach of the operator Further details will be added as the machine is completed OPERATION CAUTION THE MACHINE IS RUNNING AUTOMATICALLY WHEN SWITCH TURNED ON 1 Prior to or before operating this machinery operator must ensure that he she understood the owner s operator s manual Learn the machine s applications and limitations as well as the specific potential hazards peculiar to this machine Follow available operating instructions and safety rules carefully Do not allow hands to come in contact with the drills bit while it is in motion The work piece must be securely clamped Use a vacuum brush or rake to remove cuttings Remove burrs and chips from a drilled hole Keep drill bits clean and sharp Dull drills are a common cause of breakage Keep floor around the drill machine free of oil and grease Keep guards in place and in good working order SO JOE XE oen cube GO pe Do not remove cuttings by hand Wait until the machine has stopped running to clear cuttings with a vacuum brush or rake 10 Do not leave machines running unattended Turn power off 11 Be sure the power is shut off before changing drill bits 12 Be sure drill bit or cutting tool is securely locked in the chuck Inform the technician if the tool seems to be malfunctioning or is damaged 126 Paddle
119. that would have better performance when operating under the specified conditions 5 2 Dimensions Some the dimensions of interest in this project have already been mentioned in previous sections Production time of a paddle machine cost including maintenance and raw material cost are some of the most significant fundamental aspects of the project The final cost of the completed machine was intended to be kept under 2000 USD for future commercialization purposes Ouotes from several different companies and materials were obtained and are presented in the following section with the intension of reducing material cost 5 3 Material Selection 5 3 Paddle Material E Beam Services Inc provides cross linking and chain session services for a price of 900 to any sheet size The cross linked cost per sheet shown in the table from Horn Plastic Inc is not expensive because this was an exchange with other vendor s material The cross linked UHMW PE could not be welded and therefore was traded off with regular UHMW PE sheet We were not able to get information on the data sheet However the sample color is Orange which indicates that the UHMW PE had undergone through a process 44 Paddle Maker Machine and Material Selection Material Cost for UHMW PE Sheet Table 2 UHMW Cost Vender Name Size TxWxL Cost per Sheet Cut to length Cost CTL 37 1 4 Interstate Plastic com Ya x48 x 72 471 500 RPlastic com 2 x 48 x 120 356 3
120. the design requirements Several friction tests were performed on samples of different 12 Paddle Maker Machine and Material Selection materials to evaluate their performance under conditions similar to those that the paddles are exposed to Machine safety rules and regulations were researched extensively to assure that the prototype complies with all standards applicable to such a mechanism Elemental environmental impact and material recycling plans were explored and are presented below After the assembly of the Paddle Maker was completed several calibration trials were performed without feeding raw material to assure that all the systems were behaving properly Finally several paddles were fabricated and some final adjustments were done The machine functioned as expected and the quality of the output paddles was acceptable for the application After working on this project during last few months the main objectives were met Although satisfactory performance was achieved given the time constraints several recommendations for future work are stated in Section 10 of this report Introduction 1 1 Problem Statement Construction paddles used in a Drag a Flight Conveyor to load powder cement to incoming trucks are made of polyethylene Due to friction between the paddles and the metal frame of machine these paddles wear at a relatively fast rate resulting in unwanted maintenance costs and delays In addition paddle orders usually
121. these tests will aid in gathering all the necessary parameters pertaining to our tests The chosen parameters will be used to test and compare the new improved material to the current one being used by Rail Barge and Truck Company In addition it will be tested and compared with UHMW PE that was exposed to the cross linking process An experiment on friction and wear behavior of nitrogen ion implanted UHMW PE against ZrO ceramic was studied in China University 1 The Ball On Disc Figure 1 wear tests were performed using an UMT tester in Campbell CA The tester combined linear and 16 Paddle Maker Machine and Material Selection rotary motions in a coordinated manner while taking measurements of tribological parameters such as friction forces friction coefficient and wear depth Parameters and material used in the study were e The material had a disk shape with 10mm thickness and a diameter of 30mm e Roughness of the sample was polished to 0 2 0 4um e Ultrasonic bath and acetone as a fluid were used to clean the sample e SisN balls with 4mm diameter were used to simulate the wear of the artificial joints e Wear tests were operated in a 25 plasma solution for 10 000 cycles e A Sinusoidal Normal load of 20N 25N was applied on the Si N balls e UHMW PE disk reciprocating at fixed frequency of 0 5 Hz e The Si3N ball load frequency varies from OHz to 1 5Hz e Four tracks of wear were formed and the testing results were measured
122. tion 3 6 Design Process DASTAN wa 36 3 6 1 Material Selection Logic Diagram eene 36 3 6 2 Proposed Machine Design Logic Diagram eee 37 EN Bist seco 38 4 Project Management s sssese0ee0esseeeseeece 39 TE 39 4 2 Team Breakdown of Responsibilities Tasks and Roles rnrnrnnnvrronvrnnnrnnvrnnrvnnenvnnrnene 39 4 3 Patent Copyright Application lt lt ssw wmmwwmmewemnammmammm cen slo EM cua tov NEM en awe 40 4 4 Commercialization of the Final Product esee 42 4S DISCUSSION EE E 42 5 Engineering Design and Analysis esesseessssvssenseessvneessnneensnnesssnneensnneensnnssnsenessnnnessnonesnnvnssnnnesene 43 SL Structural Bio aan 43 Ne 44 5 3 Material SEOUL Uwa 44 5 3 1 VE EE EE EN NN 44 5 3 2 Machine Major Components aan 45 YA Force Analysis sounens n ro ie n E une A E E E ei taU 46 5 5 Dynamic Vibration Analysis wsswemamenmnnmanmanmnmmnamnm nna ninm anaimani nima 48 5 0 Deflection Ana IS e 50 5 7 Material Analysis for Machine Assemblies eese 51 5 1 1 Stress Analysis me 52 5S2 Strain Ne 53 Dis Fd Displacement ERE aa E A iua did uia eM Nest desi a 53 5 7 4 Factor of Safety analysis eeeseeseeeeeseeesesess
123. tor to the drilling shaft while reducing the speed of the motor by a ratio of 3 1 To accomplish this a combination of two timing gears was selected since no slippage between the belt and the pulleys was desired The driving pulley was chosen to be a 24 tooth Acetal Plastic with Aluminum Hub to meet the size of the motor s shaft The driven pulley was required to be 72 tooth to meet the required rpm for consistent drilling and acceptable hole finishing This last pulley was not available in any other material but steel which is heavier yet more lasting than plastic 6 2 3 Bearings All bearings used in the design and construction of the machine were picked from the McMaster catalog while keeping in mind their availability from local vendors in case replacements were to be needed in the future All bearings were selected depending on their specific function location in the machine and load carried 6 2 4 Linear Stage After estimating the weight of the finished drilling assembly a suitable linear stage was selected to withstand the torque and reaction forces created by the drilling process The selected linear stage is a MLPS 4 10 low profile series from Servo System Company capable of supporting a 10 Ibs dynamic load on a 4 travel rail The manufacturer specification sheet is attached in Appendix I of this report 57 Paddle Maker Machine and Material Selection 6 2 5 Rods and Supports After studying the shaft deflections and internal
124. ty Z AXIS MOTOR MOVEMENT PROFILE 29 2969 X Axis 2 263672 3 234375 205078 z 175781 8 146484 2 11 7188 8 78906 E 5 85938 gt 292969 Fil No File Loaded Edit G Code Recent File Close G Code Load G Code 04 015 02 025 03 Time in Seconds 035 04 045 05 SRO Spindle CW F5 100 Sf e RPM 0 Accel Set Next Line Line 0 Steps per In sormm spermin insormms sec sec Gs 1 Sus 0 5 R nEGAGiBSS 6400 25 s 0 0129509 o fo Cancel OK 1 Jog ON OFF Ctrl Alt J ReConfiguration Estop Profiles Mach3Mill S ov 0 Spindle Speed i 0 On Off Reset Emergency Mode Activ Z inhibit G Codes M Codes 0 000 Units Min 0 00 UWsRev 0 00 Figure 35 Z axis for Drill Assembly Vertical Direction Mach3 CNC Controller E g Program Run Alt 1 MDI Alt2 ToolPath Alt4 Offsets Alt5 Settings Alt6 Diagnostics Alt 7 Mill G15 G80 G17 G40 G20 G90 G94 G54 G49 G99 G64 G97 Motor Tuning and Setup Axis Selection Velocity A AXIS MOTOR MOVEMENT PROFILE X Axis 1171 88 2 105469 9375 Y Axis 820 313 z 703 125 Z Axis 585 938 No File Loaded 468 75 351 563 5 2 234 375 Edit G Code E Ld Recent File 0 0 702 04 d6 08 1 32 14 15 18 g Time in Seconds faes H Accel Id Set Next Line ee
125. ty is increased In addition because a load is applied on the sample during the tribometer test and therefore compressed on the material a question about accuracy of the LVDT h values was raised Regarding the results for the cross linking material in order to get a constant coefficient of friction the molecular bonding should be good Since data sheet for the crossed linked sample 87 Paddle Maker Machine and Material Selection was not available from the vendor a conclusion can be made to exclude this material as a comparison Regarding the new and old material when buying it from the vender one cannot be sure of the preparation and process the polymer was exposed to or if the material is homogenous or not In conclusion even though the COF is not that important the concern is with the total volume loss With the ball being compressed and with the results not as expected the conclusion was that the volume loss data might not be accurate Thus a different method of measurements needed to be obtained and is illustrated in section 7 4 1 Also since polymers have good bonding and can be compressed whereas a ceramic material for example wears out because of poor bonding a different test method such as pin on disk and not a ball on disk must be considered for the obtained polymer sheet A Pin on disk abrasive type test method where the pin is made of the UHMW PE and the disk is made of Aluminum oxide will be closer to wear condition
126. v Jun Xiao Wear behavior and wear debris distribution of UHMW PE against Si3N4 ball in bi directional sliding Journal of Polymer Wear Testing Vol 264 571 578 2008 2 S A R Hashmi Somit Neogi Anuradha Pandey Navin Chan Sliding wear of PP UHMW PE blends effect of blend composition Journal of Polymer Wear Testing Vol 247 9 14 2001 3 Shirong Ge Qingliang Wang Dekun Zhang Hua Zhu Dangsheng Xiong Chuanhui Huang Xiaolong Huang Friction and wear behavior of nitrogen ion implanted UHMW PE against ZrO2 ceramic Wear Testing Vol 255 1069 1075 2003 4 Shigley Joseph Mischke Charles Brown Thomas H Standard Handbook of Machine Design 3 edition 5 Richard G Budynas and Keith Nisbett Mechanical Engineering Design 8 edition McGraw Hill New York 2008 6 ASM Handbook Vol 8 Mechanical Testing and Evaluation ASM International Material Park OH 2000 7 JT Black Ronald A Kohser Materials and Processes in Manufacturing 10 edition John Wiley amp Son USA 2008 8 Michael Bauccio American Society for metals ASM Metal reference Book ASN International 1993 9 ASHBY M F Materials Selection and Process in Mechanical Design Butterworth Heinemann Oxford 1999 ISBN 0 7506 4357 9 10 Ashby Mike and Johnson Kara Materials and Design the Art and Science of Materials Selection in Product Design Butterworth Heinemann Oxford 2002 ISBN 0 7506 5554 2 11 Courtney T H Mechanical Behavior of Mater
127. w and vertical axis Z of drill assembly goes to zero position at the same time e Sheet mover wheels turn 16 moving the work piece to the correct cutting position e Program repeats for construction of next paddle 73 Paddle Maker Machine and Material Selection PADDLE MAKER PROGRAM gOal5 Sheet moves forward 15 degree First hole tapping drilling cycle g0z 1 5 g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 g0z 2 g0z 1 95 g0z 2 1 g0z 2 05 g0z 2 2 g0z 2 15 g0z 2 3 g0z 2 25 g0z 2 4 g07 2 35 g0z 2 6 g0z 1 g0x 5 5 Moving to second hole position Second hole tapping drilling cycle g0z 1 5 g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 gOx 11 Moving to third hole position Third hole tapping drilling cycle g0z 1 5 74 Paddle Maker Machine and Material Selection g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 g0z 2 g0z 1 95 g0z 2 1 g0z 2 05 g0z 2 2 g0z 2 15 g0z 2 3 g0z 2 25 g0z 2 4 g0z 2 35 g0z 2 6 g0z 1 g0x 22 Moving to fourth hole position Fourth hole tapping drilling cycle g0z 1 5 g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 g0z 2 g0z 1 95 g0z 2 1 g0z 2 05 g0z 2 2 g0z 2 15 g0z 2 3 g0z 2 25 g0z 2 4 g0z 2 35 g0z 2 6 g0z 1 g0x 27 5 Moving to fifth hole position Fifth hole tapping drilling cycle g0z 1 5 g0z 1 8 g0z 1 75 g0z 1 9 g0z 1 85 g0z 2 g0z 1 95 75 Paddle Maker Machine and Material Selection g0z 2 1 g0z 2 05 g0z 2 2 g0z 2 15 g0z 2 3 g0z 2 25 g0z 2 4 g0z 2 35 g0z 2 6 g0z
128. wear 10N e Wear distance 300m e Rotational speed 300 rpm or 250 rpm Considering approximately 0 1 m s e Wear track diameter 6mm Al gt O3 ball e Time 50 min 3000sec e Calculation for time and rpm Distance 300m Time 3000s V 0 1 8l Paddle Maker Machine and Material Selection Velocity 0 1 60s midia 1 0 006m 1min rpm 300rpm Figure 40 Ceramic Abrasive Ball on UHMW PE Disc Test New Old Crosslink Material Material Material Figure 41 Tested Samples 82 Paddle Maker Machine and Material Selection Results and Data Lab notes for weight loss obtained during test are in Appendix M Excel data for all tracks are included in the CD Excel data result in Appendix N contains only a sample of 50 data points out of 52 260 The Nanovea software for the tribometer tester gives 15 to 20 data points per second Total time for each track was 50 minutes The software displays values of distance meters Coefficient and Ceramic ball Depth mm The two graphs below show wear volume loss and coefficient of friction values for all three samples Old Material New Material and Crosslink Material 30 TT 1st Test mH 2 nd Test 25 Wear Volume Loss mm Old Sample Orange New Sample Figure 42 Wear Volume Loss Comparison 83 Paddle Maker Machine and Material Selection COF 1 0 e Black Sample Old o Orange Sample 0 84 Bla
129. wise located so that the employee cannot inadvertently come in contact with hazardous moving parts OPERATION Do Not Ride Step Sit or Climb on Conveyor A conveyor shall be used to transport only material it is capable of handling safely The work piece must be securely clamped before turning machine ON Don t perform service on conveyor until motor disconnect is Locked Out Inspections and preventive and corrective maintenance programs shall be conducted to insure that all safety features and machine parts are functioning properly Keep clothing fingers hair and other parts of the body away from conveyor Don t load conveyor outside of the design limits 6 7 8 9 Don t remove or alter conveyor guards or safety divides Know location and function of stop start push button 10 Keep all stopping starting control devices free from obstructions 120 11 12 Paddle Maker Machine and Material Selection Ensure all personnel be clear of conveyor before starting Report all unsafe practices and machine parts to your manager MAINTENANCE Maintenance such as lubrication and adjustments shall be performed only by gualified and trained personnel It is important that a maintenance program be established to insure that all conveyor components are maintained in a condition which does not constitute a hazard to personnel When a conveyor is stopped for maintenance purposes starting devices or powered acc
130. x Adjustable Speed Motors Heavy Duty with fan 140 Watt 100mm ma p The value in the is the value for the small gear shaft motor Allowable Model Out Start Capaci Volt Freq Poles Speed Torque put Duty d Torq tance Motor with gear 1200r 90r Motor shaft Ww V Hz P rpm N m N m N m pF VAC 0 85 6IK140RA 61K140 AF RGU AF adjustable adjustable speed 140 1phi110 50 4 CONT 90 1350 speed motor w gear motor shaft 5IK140RA 61K140 CF RGU CF adjustable adjustable speed 140 1ph220 50 4 CONT 90 1350 0 85 0 45 0 68 10 0 450 speed motor w gear motor shaft The required capacitor value will vary depending on operating voltage A correct capacitor is required to o 45 0 62 30 0 250 match the applied voltage 137 Paddle Maker Machine and Material Selection General Motor Characteristics Insulation Resistance 100MQ at 500V between motor winding and shell Insulation Voltage 1500V 50 60Hz imin between motor winding and shell Temperature Rise Max 80 C Insulation Class Class B 130 C Operating Temperature 10 C to 40 C Three phase 10 C to 50 C Humidity 85 max 138 Paddle Maker Machine and Material Selection Appendix M Material Lab Notes Tvibomelev Jes t Pavamekvr Asttvecle Et So nin Mstanu 300 w Din vk G mn And Wade VAN A1203 Amg Loo JON old Samt Ask tect Taha Wahl 3 80 18 g Suyfau Vuth
131. y O L ess A 1 s H305 Lom Hon 1421 gt I 10 1487 Avg h2 0OT Wight Time 4 ar trer tet ANS lof noli Loss GC Less c an of Ct garn gt 9 0 09105 Act hay 50 my 3 Pol 9 Oud track SOngs 2 PIGA Oran Sami 2w tert Xwha Wevaht 4 241 4 Sorton vufeui 95624 Gy 0395 9 701 AX tos C 2 0 000 lay nh wt A s Tangi SOmin ud D Tvade SO my 9 new samp Bva test Taiha WA i 3 403 069 s ji ifu yYuffwusy LYN 0 516 l 044 1 07 0 662 0 94 Tive E 1375 ANS 0 996 Ww Might Loss Tie Som 3 116 745 E 0 00ol1 ko 9 0 0013 Tan 99 246243 9 139 Paddle Maker Machine and Material Selection AMRI lob OMM test to weary WE 19 I X40 Olympus fuv foce 9 990 Wa V SX2 x o NW jue Ast Trate bii Toe See e VI ac 0 1G S 16 kg Me ls Ue Avs awd Vek MIT 6 jx AS 9 amp From 48 13 3 aude dq 9 te 6 gt 43 o ja ios 13 old E ES ou d Groen Ter Diff Ast tock S EN n o 14 19 9 20 5 20 5 2 INS 95 d 16 SS 18 Ay Cua Tea K 49 2 2 5 6 3 s 5 19 Ploy ey 6 20 ST 86 7 21 20 w ph 9 Sarre yy VU 33 n2 o IP 35 2 e pr 140 Paddle Maker Machine and Material Selection Appendix N Material Testing Data Samples 0 0091000 0 137471362 0 586952367 0 0098833 0 133930433 0 590283882 0 0109333 0 14455322 0 591192477 0 0117167 0 141428871 0 594221
132. y recommended a simple method of analysis in order to find an approximation of the first natural frequency that could be compared to the frequency that the motors are running at He suggested that if the natural frequency of the system is different than the natural frequency of all motors then no resonance will occur and the design would be safe of critical vibrations If the system frequency falls within 10 of the natural frequency of any motor it is not considered safe and a simple vibration absorber composed of springs and mass should be used The paddle maker machine is formed by several subsystems namely the drilling station sawing assembly and a roller table For that reason it was chosen to use Dunkerley s formula 31 to determine the system s final natural frequency Dunkerley s formula gives approximate 48 Paddle Maker Machine and Material Selection values of the fundamental frequency of a composite system in terms of the natural frequencies of its components The fundamental frequency showing in Figure 19 was used to include all subsystems Figure 19 Dunkerley Formula Used for the System The natural frequency formula is w J k m where k is the spring coefficient and m is the mass gt K equivalent and total Mass for each subsystem was calculated e Roller Conveyor assembly The legs experience the same deflection thus the k equivalent is in parallel They were simulated as fixed beams of circular cross section Th

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