Group_13_Final_Presentation

9/20/2015Group 13
Final Presentation
By: Brendan Keane, Logan McCall, Reggie Scott, Mark Swain
Instructor: Dr. Nikhil Gupta
Sponsor: Dr. Philip Flater (Air Force Research Laboratory Eglin AFB)
Advisor: Dr. Simone Hruda

9/20/2015
Group 13 Speaking:
1 of 27 Final Presentation
 Introduction
 Design and Analysis
 Prototype Testing
 Project Management
 Conclusion
Overview
Reginald Scott

Group 13 Speaking:
9/20/2015
 Current torsion tester at the
Air Force Research
Laboratory (AFRL) Munitions
Directorate at Eglin AFB is
approximately 5 meters in
length
 Small sample geometries
result in inaccuracy and
inefficiency
Introduction
Figure 2.1: Existing Torsion Machine
“DISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)”
Reginald Scott

Group 13 Speaking:
9/20/2015
 Small specimens are a
result of original plate
stock dimensions
 Specimens tested:
 Aluminum 2024
 Titanium 64
Specimen Geometry
Original plate stock
Blank removed
Sample machined
Figure 3.1: Specimen production
Dimension Measurement (mm)
Total Length 58.4
Gauge Length 12.7
Width 14.3
Inner Diameter 9.09
Fillet Radius 27.9
Grip Length 20
Table 3.1: Specimen dimensions
Reginald Scott

Group 13 Speaking:
9/20/2015
 Maximum torque output: 100Nm
 Machine must fit in an area (footprint) of 1m2
 Monotonic (one direction) free-end torsion loading
 Free end must allow for axial motion
 Compatible with measurement equipment used by AFRL
 Budget - $2,000
Design Requirements
Reginald Scott

Group 13 Speaking:
9/20/2015
Goal Statement:
Design a more effective way of testing small specimens in
free-end torsion
Design Requirements
Reginald Scott

Group 13 Speaking:
9/20/2015
DIC (Digital Image Correlation)
Figure 6.2 Example DIC use in torsion
sample
Figure 6.1 DIC setup at Eglin AFRL
Brendan Keane

Group 13 Speaking:
9/20/2015
 Current method used by
AFRL to measure applied
stress:
 Strain gage placed on
elastic bar
 Use shear modulus
relationship to output
stress
Load Measurement
Figure 7.1: Stress vs. strain plot showing the
shear modulus relationship
G =
𝜏
𝛾
Brendan Keane

9/20/2015
Group 13 Speaking:
Torsion Tester
Load Generation
Manual Power
Motor & Transmission
Load Application Gripping Mechanism
Load Measurement Compatibility
Linear Motion Friction Reduction
Frame
Material Selection
User Safety
Breakdown of Design
Brendan Keane

9/20/2015
Group 13 Speaking:
Load Generation
Design Cost Weight Accuracy Complexity Maintenance Variability Total
Weight Factor 0.25 0.05 0.25 0.1 0.1 0.25
(1) Crank System 5 3 1 5 5 1 2.9
(2) Hydraulic 1 1 5 1 1 5 3
(3) AC Motor 3 3 5 3 3 5 4
(1) (2) (3)
Brendan Keane

9/20/2015
Group 13 Speaking:
Load Application
Design Cost Weight Reliability Complexity Variability Total
Weight Factor 0.25 0.15 0.3 0.1 0.2
(1) 3-Jaw Chuck 5 5 5 3 5 4.8
(2) 4-Jaw Chuck 3 5 5 3 1 3.5
(3) Self-Aligning
Vise
3 1 3 5 5 3.3
(4) Collet 5 5 5 3 1 4
(1) (2) (3) (4)
Brendan Keane

9/20/2015
Group 13 Speaking:
Linear Motion
Design Cost Weight Durability Complexity Total
Weight Factor 0.4 0.2 0.2 0.2
(1) 4 Rail Ball
Bearing Guide
1 2 1 1 1.4
(2) 2 Track Roller
Bearing Guide
3 5 5 5 4.2
(3) 2 Rail Ball
Bearing Guide
5 5 3 3 4.2
(1) (2) (3)
Brendan Keane

9/20/2015
Group 13 Speaking:
Frame
 Design Considerations:
 Strength
 Machinability
 Weight
 Cost
 Material Selection:
 Steel
Figure 12.1: Frame design
Brendan Keane

9/20/2015
Group 13 Speaking:
Concept Evolution
Brendan Keane

9/20/2015
Group 13 Speaking:
Figure 5.1: CAD representation of design
Design Overview
Logan McCall
Steel Shaft
32”
13”

Group 13 Speaking:
9/20/2015
 Vendor: Grainger
 Rpm: 18
 Gear ratio: 95:1
 Max torque: 116 Nm
 Weight: 26 lbs
Load Generation: AC Gearmotor
Figure 15.1: AC Gearmotor
Logan McCall

Group 13 Speaking:
9/20/2015
 Vendor: Automation
Direct
 Single phase input, three
phase output
 Digital keypad
 Forward and reverse
 Expandable
Motor Control: VFD
Variable Frequency Drive (VFD)
Figure 16.1: VFD keypad
Logan McCall

Group 13 Speaking:
9/20/2015
 Vendor: LittleMachineShop
 Weight: 6.4 lbs
 Outer diameter: 3.94 in (10 cm)
 Inner diameter: 1.02 in (2.59 cm)
Load Application: 6-Jaw Chuck
Figure 17.1: 6 Jaw Chucks holding specimen
Logan McCall

9/20/2015
Group 13 Speaking:
Load Measurement
 Coupler material: Al 6061
 Coupler properties
 Shear modulus: 26 GPa
 Shear strength: 76 MPa
 Outer diameter: 1.75 in (4.45 cm)
 Inner diameter: 0.75 in (1.90 cm)
Figure 18.1: FEA performed on coupler
showing strain developed under a
simulated load
Logan McCall

Group 13 Speaking:
9/20/2015
 Vendor: Grainger
 ½ inch steel rails
 Slot design to ensure
alignment
Linear Motion: 2 Rail Ball Bearing Guide
Figure 19.1: Linear guide system
Logan McCall

9/20/2015
Group 13 Speaking:
Frame Design
 Steel frame
 Shape: hollow square
shaped cross-section
 Dimensions:
 1/8 in inner supports –
304 stainless steel
 1/8 in outer frame –
low carbon 1015 steel
Figure 20.1: CAD drawing of frame (bottom view)
Logan McCall

9/20/2015
Group 13 Speaking:
Final Design
Logan McCall

9/20/2015
Group 13 Speaking:
Prototype Testing
Mark Swain

9/20/2015
Group 13 Speaking:
 Tester was successful in breaking
aluminum specimen
 Fracture was at center
 During initial testing, free end chuck had
slight rotation
 Solution: Force fit new connecting
rod into free end
 Cylindrical grips slipped during initial
testing
 Solution: Use hex-grip specimen or
increase friction on cylindrical
specimen
Testing Results
Figure 23.1: Fractured
specimens
Mark Swain

9/20/2015
Group 13 Speaking:
Budget
44%
25%
18%
10%
3%
Load Generation Load Application
Linear Motion Housing
Miscellaneous
 Budget: $2,000
 Spent: $1,844
 Net: + $156
Mark Swain

9/20/2015
Group 13 Speaking:
Project Progression
Fall
 Background research
 Design breakdown
 Component research
 Design analysis
 Optimal part selection
 Budget breakdown
 Purchase orders
Spring
 Delivery of parts
 Machining
 Assembly
 Motor/VFD testing
 Prototype testing
 Troubleshooting
 Final assembly
Mark Swain

9/20/2015
Group 13 Speaking:
Conclusion
 Maximum torque output: 100Nm
 Machine must fit in an area (footprint) of 1m2
 Monotonic (one direction)free-end torsion loading
 Free end must allow for axial motion
 Compatible with measurement equipment used by AFRL
 Budget - $2,000
Mark Swain

9/20/2015
Group 13 Speaking:
 The team was successfully
designed and
manufactured a tabletop
torsion tester for AFRL
 What we learned:
 Focus on the main
customer requirements
 Consult as many
resources as possible
 Teamwork is essential
 Unforeseen
circumstances
Conclusion
Figure 27.1: Final assembly
Mark Swain

9/20/2015
Group 13 Speaking:
 Carter, B. (2008). Texas Instruments: Op Amp Noise Theory and Applications. Retrieved
September 22, 2014
 Flater, P. (2014). Tabletop Torsion Test. Eglin, FL: Air Force Research Laboratory.
 Ilic, M. (2014, October 11). Clamp for centering. Retrieved from GRABCAD:
https://grabcad.com/library/stega-za-centriranje-clamp-for-centering-1
 Lathe Chuck. (2014, October 7). Retrieved from GRABCAD:
https://grabcad.com/library/lathe-chuck-3
 Linear Motion Systems. (2014, September 28). Retrieved from Stock Drive Products:
https://sdp-si.com/eStore/coverpg/linearmotion.htm
References
Mark Swain

9/20/2015
Group 13 Speaking:

9/20/2015
Group 13 Speaking:
Fall Gantt Chart

9/20/2015
Group 13 Speaking:
Spring Gantt Chart

9/20/2015
Group 13 Speaking:
Specimen Dimensions
Brendan Keane
Units in inches

9/20/2015
Group 13 Speaking:
Appendix

9/20/2015
Group 13 Speaking:

9/20/2015
Group 13 Speaking:
Part # Part
Name
Description Quantity Unit
Cost
Supplier Cost
Load Generation
6Z404 Motor AC Gear Motor, 18rpm,
TEFC, 208 - 230/460V
1 $601.56 Grainger $601.56
GS2-
10P5
VFD Variable Frequency Drive,
0.5 HP, AC Drive
1 $166.00 Automation
Direct
$166.00
Load Application
2276 Lath
Chuck
6-Jaw, 4" Outer Diameter 2 $174.95 Little
Machine
Shop
$349.90
Linear Motion
2HXB4 Rails 0.5in Thick(Annealed
Shaft, Steel, 0.500in
D,16in)
2 $41.80 Grainger $83.60
2CNL6 Pillow
Blocks
0.5in. (PillowBlock, 0.500
in. Bore, 1.690in L)
4 $41.83 Grainger $167.32
2CNU7 Shaft
Support
0.5in. (Shaft Support,
0.500 in. Bore, 1.625in. H)
4 $25.99 Grainger $103.96
Frame
2HHP8 Motor
Shim
0.75in stock (Bar, Rect.,
Steel, 1018, 3/4 x 1in, 1Ft.
L)
1 $9.05 Grainger $9.05
3DRT8 Motor
Baseplate
0.125in Sheet (Flat Stock,
LCS, Hot Rld., 1/8in T,
1Ft. L)
1 $16.49 Grainger $16.49
3DRU7 Free End
Baseplate
0.25in Sheet (Flat Stock,
LCS, Hot Rld., 1/4in T,
1x1 L)
1 $22.59 Grainger $22.59
3DRR5 Long
Support
Tube
0.125in Th (Tubing, Sq,
1015 LCS, 1OD x 1/8in T,
6 Ft. L)
2 $19.71 Grainger $39.42
4YUL5 Small
Thick
Support
0.25in Th (Sq Tube,
304SS, 1 OD Sq x 3/4 ID
Sq 6ft)
1 $47.48 Grainger $47.48
2HHW5 Free End
Stand
1in Stock 1 $25.55 Grainger $25.55
2EYG6 Rod Aluminum 6061, 4in D x
12in L
1 $105.70 Grainger $105.70
8290T15 Rod Unpolished, 1117 Carbon
Steel, 0.75in D x 12in L
1 $7.79 McMaster $7.79
Miscellaneous Costs $98.54
Total Cost $1,844.95

Group_13_Final_Presentation

Recomendados

Recomendados

Mais conteúdo relacionado

Destaque

Destaque (10)

Semelhante a Group_13_Final_Presentation

Semelhante a Group_13_Final_Presentation (20)

Group_13_Final_Presentation