Requirements
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Cut composite material with one initial push into the delamination device
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Transfer power from motor to sprocket by way of chain to rotate 600 RPM
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Cut composites into 1 in strips
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Use a federate of 100 in/m
Parameters of Interest
The group is interested if the prototypes developed will be able to delaminate and cut the composite scraps that were provided by Boeing and John Locklear. We were under the impression that we would develop prototypes like we stated in our proposals through research and initial experiments. For delamination, we used a Baleigh press to see how much force was required to delaminate a piece of composite. From there, we used a wedge and a hammer to see how much force was required to split a single layer of composite. With these values, we designed devices to perform the delamination and cutting in two processes by way of electric motors. If successful, we would scale these devices and operations into a full warehouse where processing could happen.
Predicated Performance
Based off the experiments that we ran during the fall, we predicted that our devices would in theory work. Coming from the little experience we had with any machine building or designing, we approached this problem the only way we knew how, which was conducting experiments to get initial values.
Data Acquisition
Data acquisition for this project has proven to be a lot more difficult then we had imagined. We were under the impression that we would make prototypes of the design we produced in fall. We did not know what we needed a frame for all components or that they needed to be connected until the final week of winter quarter. For spring quarter, we have been trying to make up a frame that will be able to house both devise, two motors, a gear reduction and various other components that have been recommended to us. We have no experience in frame design, but luckily were able to find one that we may use. With the existing frame, we are going to add tubing and legs so that it can withstand near 300 lbs of devices and material. We will need a lab technician to weld our tubing onto the existing frame and are not sure if a fixture will also need to be made.
But once a frame is completed, assembled with all the components, motors are wired, connected to grid, and proven to be safe with all the components fastened and secured, then we can run a test. We will power on both motors and get a reading of how fast each devices sprocket are rotating. One of the members will insert a composite strip into the dominator which will push it into the cutting device. Depending on whether strips are being delaminated or cut, we may have to resize our sprockets so that the devices will be operating at a different speed.
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The provided spreadsheet shows when and how long tasks took to complete. Everything from numbers 1-7 are complete accept for 7k. 7k is the frame modeling that still needs to be completed prior to testing. It is evident that the predicted time and actual time differ significantly. We used conservative prediction because once manufacturing started, it was evident that all tasks were going to take a lot longer than anticipated. Just getting the housing for the cutter to line up took an extra 4 hours because holes needed to drilled to a higher size and tapped again as an example.
Method/Approach
Resources
JCATI funded our project. Thanks to there funding, we were able to build our proposed devices and buy motors for each device. They pledged $5000.00 for the project.
John Locklear from Boeing provided us initial guidance with the project and proposed the project last year in our Plastics and Composites class. The dialogues we had with him during the first two quarters really helped understand the scope of this project.
Dr. Johnson helped with initial designs and would check in to see progress.
Professor Pringle would take time to help with the many issues we encountered. He mentored us during the design and manufacturing portion.
Matt Burvee allowed us to make our designs into a actual device. Thanks to Matt, a lot of time was saved due to his experience. He would also be hands on when doing an intricate machine process like the keys on my shafts.
Tedman Bramble was also crucial when manufacturing my housing. Thanks to Ted, the gears that are connected to the shaft were able to mate due to the placement of the holes.
Data Capture
Once data is captured, we will include a table or a graph in this section. Whichever form of representation that is best.
Test Procedure Overview
The test procedure which will be shown in detail in the following section is designed so that once both motors are on, an initial push of a single composite piece will be able to travel through both phases.
Operational Limitations
The operational limitation of this test will be the RPM of both devices. If the devices do not perform their operations, it is possible that a different size sprocket would suffice. An issue for this is that the shafts that house the sprockets were machined to hold the sprocket that are currently on and new ones may have to be made.
Another operational limit will be the size of the frame. The stand that we found is already built, so any modifications will have to me made so that they can fit.
Precision and Accuracy Discussion
Our RPM will be precise because the sprockets purchased and chain will provide a RPM once the motor is running at its full 1750 RPM.
Data Storage/Manipulation/Analysis
Data will be stored in tables or on excel. They will also be manipulated in these programs.
Data Presentation
Data will also be presented in excel or word. It will be attached to the appendix of the final report.
Test Procedure
Summary/Overview
The test will consist of feeding a single piece of composite into the delimitator which will push the piece of composite into the cutter. There will be a bin attached to the open end of the cutter which will catch cut material.
Time/Duration
The time of the overall test will be dependent on the rate that the delaminator feeds material through the entire system. At a federate of 100in/m, it will take about 1 minutes to travel through the entire system.
Place
The location is still undetermined due to the amount of power that will be required to run both motors. But the metallurgy lab or foundry lab will probably be where the test is conducted.
Resources Needed
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Lab that can power motors
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Composite materials
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Frame for both devices manufactured and fastened
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Safety glasses
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Emergency stops for motors
Specific Actions to Complete Test
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Make sure all components and devices are secured. Tighten all bolts with allen wrench so that they are snug and cannot move.
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Make sure all alignment of devices and motors is correct. Sprockets should be allowed to rotate by hand prior to starting motors. If there are alignment issues and sprockets are not rotating, dissemble and re assemble so that they can rotate.
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Insert a bin to collect cut material at the end of the shredder. The end of the device is 10” x 8”. A bin larger then that will have to be attached to the end of the cutting device.
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Separate the blades by using to spacers so that they are ½” apart. They already provided an located on both shafts.
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Power both motors. They have yet to be wired nor do they have switches or power buttons. Updates will be added once more information is given.
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Record the RPMs each device is running at. Using a tachometer, record these values in the table provided.
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Feed composites into the delamination device. The delamination device is the shorter of the two, and will be facing the operator.
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Observe to see if delamination is happening. If delamination occurs, leave power on so that material can be fed into shredder. Layers will start to break apart.
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If no delamination occurs, the power off the motors.
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Change the sprockets and chain of delamination device to produce either a higher or lower RPM.
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If test is successful, power both motors off.
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Allow for all moving components to come to a complete stop.
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Unplug motors.
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Remove composite material.
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Remove the bin and observe the physical state of the material that is gathered.
Risk/Safety/Evaluation Readiness/Other
The risk of running these devices is that they can potentially be dangerous if the alignment of motors and sprockets is not correct. Also, there is a potential danger if the devices are not secured. Anyone who is running this test must be aware of moving and rotating parts and stay clear of them. Once powered, the only point of contact should be feeding material into the delamination device. Any manipulation of parts or devices must be done with motors not powered, and all components at a complete stop.
The test is not ready to be conducted. Upon completion of a stand for the delamination device, wired motors, and a frame for both devices, then a test can be run.
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