ME 462 Final Project Hydraulic Press Support...
Transcript of ME 462 Final Project Hydraulic Press Support...
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ME 462 Final ProjectHydraulic Press Support Frame
Bishop IThursday, May 5, 2005
Luke Jones
Stephen Leybourn
Andrew Placek
Andy Sutton
Team Members:
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Project Background
Bishop discovered that there is a market for a movable cylinder, rack and pinion driven, hydraulic pressBishop has since developed a fixed cylinder, 15 ton prototype
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Key RequirementsSupport 15 ton hydraulic press loadMobile cylinder – 16” total stroke
2” increments8”-10” travel
Minimized cost$1700 initial budget for entire pressFirst prototype was $7000
Comfortable factor of safetyMinimum deflection
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Conceptual DesignBenchmarksQFDFunctional decomposition6 overall conceptsFailure Mode Effects AnalysisDecision matrixFinal concept
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Design Modeling
Pro-E WildfireDesign evolution
Runner Plate
Slotted guide
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FEA Analysis (continued)
AnsysSOLID 185 Element
Deflection, Von Mises
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FEA Analysis (continued)
Frame components
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FEA Analysis (continued)
Also considered various load conditions1”
Side
Back
Side
Front
Point Load
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FEA Analysis (Continued)
Pro-E Mechanica- Von Mises
15,000 psi max
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Design Optimization
Side plate thickness optimized to obtain required safety factorNon-critical plate thicknesses reduced to ¼”
Frame weight reduced by 30%Standard part purchasing
BoltsReservoirPlate thicknesses
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Final Product
C-frame supportSide mounted cylinderSlotted guide systemFive increments of adjustmentLocking pins
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Engineering Targets
Engineering Targets Target (Delighted) Target (Disgusted)Max Load 15 Ton 10 TonAdjustment 5 4Cost $400 $1,000Deflection 0.01" 0.05"Factor of Safety 3 1
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Load Evaluation
15 ton capacityAcceptable stress levelsStandard C-frame
Proven design¾” A36 steel
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Adjustment Capability
Adjustments5 – 2” increments
Plate & guide conceptPin locking designVerified by FEA Analysis
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Cost Evaluation
$400 budgetSteel recommendationAnalysis required ¾” steel in support areas$1100 via non-bulk purchasing Bulk purchasing could equate to 40%-60% reduction in cost
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Stiffness Evaluation
Target set at 0.01” magnitude deflectionAnalysis resulted in a 0.019” maximum deflection magnitude
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Factor of Safety
Requirement set at 3Analysis revealed a factor of safety of >3 on frame design, ~2.5 guide system designGauge reduction of non-critical plates resulted in no impact to factor of safety
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Engineering Targets Met
Supports hydraulic press and subsequent loading forcesSafety factorStiffnessNumber of incrementsCylinder MobilityBase square footageOperator height range
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Engineering Target Opportunities
CostBulk purchasing could reduce target vs. actual cost gap
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Conclusion
Design achieves required capabilities related to product performance Realistically approaches cost with respect to non-bulk purchasing Successful design
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Acknowledgements
Jason Wou, Bishop SteeringDave Call, machining expertRick Jones, welding expertDr. Chen, professorKittisak “Tony” Koombua, grad student
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Questions