Group_13_Final_Presentation

PowerPoint Presentation

Final PresentationBy: Brendan Keane, Logan McCall, Reggie Scott, Mark SwainInstructor: Dr. Nikhil GuptaSponsor: Dr. Philip Flater (Air Force Research Laboratory Eglin AFB)Advisor: Dr. Simone HrudaTabletop Torsion Device

4/15/2015Group 13

IntroductionDesign and AnalysisPrototype TestingProject ManagementConclusionOverviewReginald Scott

4/15/2015Group 13Speaking: # of 27Final Presentation

Current torsion tester at the Air Force Research Laboratory (AFRL) Munitions Directorate at Eglin AFB is approximately 5 meters in lengthSmall sample geometries result in inaccuracy and inefficiency

Introduction

Figure 2.1: Existing Torsion MachineDISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)Reginald Scott

Group 13Speaking: # of 27Final Presentation

4/15/2015

Small specimens are a result of original plate stock dimensionsSpecimens tested:Aluminum 2024Titanium 64Specimen Geometry

Original plate stockBlank removedSample machinedFigure 3.1: Specimen productionDimensionMeasurement (mm)Total Length58.4Gauge Length12.7Width14.3Inner Diameter9.09Fillet Radius27.9Grip Length20

Table 3.1: Specimen dimensionsDISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)Reginald Scott


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Maximum torque output: 100NmMachine must fit in an area (footprint) of 1m2Monotonic (one direction) free-end torsion loading Free end must allow for axial motionCompatible with measurement equipment used by AFRLBudget - $2,000

Design RequirementsReginald Scott


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Goal Statement:Design a more effective way of testing small specimens in free-end torsion

Design RequirementsReginald Scott


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DIC (Digital Image Correlation)DISTRIBUTION A: Approved for public release, distribution unlimited. (96ABW-2014-1649)Figure 6.2 Example DIC use in torsion sample

Figure 6.1 DIC setup at Eglin AFRLBrendan Keane


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Current method used by AFRL to measure applied stress:Strain gage placed on elastic barUse shear modulus relationship to output stressLoad MeasurementFigure 7.1: Stress vs. strain plot showing the shear modulus relationship

Brendan Keane


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Breakdown of Design

Brendan Keane


Load GenerationDesignCostWeightAccuracyComplexityMaintenanceVariabilityTotalWeight Factor0.250.050.250.10.10.25(1) Crank System5315512.9(2) Hydraulic1151153(3) AC Motor3353354

(1)(2)(3)Brendan Keane


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Load ApplicationDesignCostWeightReliabilityComplexityVariabilityTotalWeight Factor0.250.150.30.10.2(1) 3-Jaw Chuck555354.8(2) 4-Jaw Chuck355313.5(3) Self-Aligning Vise313553.3(4) Collet555314

(1)(2)(3)(4)Brendan Keane


Linear MotionDesignCostWeightDurabilityComplexityTotalWeight Factor0.40.20.20.2(1) 4 Rail Ball Bearing Guide12111.4(2) 2 Track Roller Bearing Guide35554.2(3) 2 Rail Ball Bearing Guide55334.2

(1)(2)(3)Brendan Keane


Frame

Design Considerations:Strength Machinability WeightCostMaterial Selection:Steel

Figure 12.1: Frame design Brendan Keane


Concept Evolution

Brendan Keane


Figure 5.1: CAD representation of design Design Overview Logan McCall

Steel Shaft

3213


Vendor: GraingerRpm: 18Gear ratio: 95:1Max torque: 116 NmWeight: 26 lbs

Load Generation: AC GearmotorFigure 15.1: AC Gearmotor

Logan McCall


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Vendor: Automation DirectSingle phase input, three phase outputDigital keypadForward and reverseExpandable

Motor Control: VFDVariable Frequency Drive (VFD)Figure 16.1: VFD keypad

Logan McCall


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Vendor: LittleMachineShopWeight: 6.4 lbsOuter diameter: 3.94 in (10 cm)Inner diameter: 1.02 in (2.59 cm)

Load Application: 6-Jaw ChuckFigure 17.1: 6 Jaw Chucks holding specimen

Logan McCall


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Load MeasurementCoupler material: Al 6061Coupler propertiesShear modulus: 26 GPaShear strength: 76 MPaOuter 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


Vendor: Grainger inch steel railsSlot design to ensure alignment Linear Motion: 2 Rail Ball Bearing GuideFigure 19.1: Linear guide system

Logan McCall


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Frame DesignSteel frame Shape: hollow square shaped cross-sectionDimensions:1/8 in inner supports 304 stainless steel1/8 in outer frame low carbon 1015 steel

Figure 20.1: CAD drawing of frame (bottom view)

Logan McCall


Final Design

Logan McCall


Prototype Testing

Mark Swain


Tester was successful in breaking aluminum specimenFracture was at centerDuring initial testing, free end chuck had slight rotationSolution: Force fit new connecting rod into free end Cylindrical grips slipped during initial testingSolution: Use hex-grip specimen or increase friction on cylindrical specimenTesting Results

Figure 23.1: Fractured specimens

Mark Swain


BudgetBudget: $2,000Spent: $1,844Net: + $156

Mark Swain


Project ProgressionFall Background researchDesign breakdownComponent researchDesign analysisOptimal part selectionBudget breakdownPurchase orders

SpringDelivery of partsMachining AssemblyMotor/VFD testingPrototype testingTroubleshootingFinal assemblyMark Swain


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ConclusionMaximum torque output: 100NmMachine must fit in an area (footprint) of 1m2Monotonic (one direction)free-end torsion loading Free end must allow for axial motionCompatible with measurement equipment used by AFRLBudget - $2,000

Mark Swain


The team was successfully designed and manufactured a tabletop torsion tester for AFRLWhat we learned:Focus on the main customer requirements Consult as many resources as possibleTeamwork is essentialUnforeseen circumstances Conclusion

Figure 27.1: Final assembly

Mark Swain


Questions?

4/15/2015Group 13

Carter, B. (2008). Texas Instruments: Op Amp Noise Theory and Applications. Retrieved September 22, 2014Flater, 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-1Lathe Chuck. (2014, October 7). Retrieved from GRABCAD: https://grabcad.com/library/lathe-chuck-3Linear Motion Systems. (2014, September 28). Retrieved from Stock Drive Products: https://sdp-si.com/eStore/coverpg/linearmotion.htm

ReferencesMark Swain




Fall Gantt Chart


Spring Gantt Chart


Specimen Dimensions

Brendan KeaneUnits in inches


Appendix




Group_13_Final_Presentation

Documents

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