Gr_3_Ph_2_Report_Mold_Handler_DDGHS_MYA_REDACT

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Symmetrically Locating Rotation Assist Mold Handler Phase 2 Report: Conceptual Design Report Prepared for:
9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Nov 4, 2019 Subject: Mold Handler - Phase 2: Conceptual Designs Dear Mr. Ostashek, We are pleased to present the Phase 2: Conceptual Designs report for the Mold Handler Design. The following topics are discussed in the report: ● Description of three design concepts (Lead Screw, Belt Drive, and Scissor) ● Design Evaluation Matrix ● Preliminary cost and manufacturing estimates ● Project schedule The three design concepts were analyzed, and the Lead Screw design was selected for the final detailed design phase of the project. Upon completion of this report, a total of 588 hours have been allocated to this project and 208 hours are estimated for Phase 3. A final report with a completed design will be submitted on Dec 2nd, 2019. If there are any questions or concerns in regards to the Phase 2 report, please feel free to contact the project manager, Andrew Doktor, at adoktor@ualberta.ca . We look forward to moving forward with the final design. Sincerely, Cc. Dr. Kajsa Duke, University of Alberta
i 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Executive Summary Levoroto has agreed to design an improved mold box handler capable of lifting a variety of sizes of mold boxes around Norwood Foundry. The mold handler shall differ from the existing design by being capable of indexing the lifting arms symmetrically to ensure the mold boxes are always balanced. Three viable conceptual designs were generated and analyzed. The first concept, the Lead Screw, involves the mold handle r arm mounted on a 90” long box beam, with indexing being driven by a lead screw with opposite hand threads on each end. Rotary input on the lead screw will linearly index the two arms equally and oppositely in the desired direction. The second concept, the Belt Drive, indexes the arms on the box beam using a belt system. The arms are connected on opposing sides of the belt such that when the belt is moved, the arms move in opposite directions from one another. The third concept, the Scissor, uses a hydraulic actuator to open the arms for positioning around the mold box. Collapse of the arms is achieved through release of pressure in the piston. The three concepts were assessed using a design matrix that was generated from the design specification matrix that Levoroto presented to the customer at the beginning of the contract. The Lead Screw concept was determined as the best option for detailed design in Phase 3. In Phase 3, Levoroto aims to carry out further detailed calculations including FEA simulation on critical components and detailed costing among other items. In order to perform the analyses outlined in the Phase 2, 230 engineering hours ($ 20,955 CAD in billing costs) were required.
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ii 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Contents Executive Summary ....................................................................................................................... . . i List of Figures ............................................................................................................................. . ... i i List of Tables ................................................................................................................................. i ii Introduction ..................................................................................................................................... 1 Concept Description ........................................................................................................................ 1 Concept 1 - Lead Screw .............................................................................................................. 1 Analyses Completed for Lead Screw Design ......................................................................... 2 Concept 2 - Belt Drive ................................................................................................................ 3 Analyses Completed for Belt Drive Design ............................................................................ 5 Concept 3 – Scissor ..................................................................................................................... 5 Analyses Completed for Scissor Design ................................................................................. 7 Design Decision Matrix .................................................................................................................. 8 Future Work .................................................................................................................................. 11 Project Management ..................................................................................................................... 12 Conclusion .................................................................................................................................... 13 References ..................................................................................................................................... 13 Appendix A - Detailed Drawing of Trunnion ............................................................................... 14 Appendix B - Brainstorming Process ........................................................................................... 16 Appendix C - Lead Screw Concept Calculations ......................................................................... 19 Appendix D - Cost Analysis ......................................................................................................... 46 Appendix E - Belt Drive Concept Calculations ............................................................................ 50 Appendix F - Scissor Concept Calculations ................................................................................. 75 Appendix G – Design Decision Matrix ........................................................................................ 97 Appendix H – Updated Gantt Chart ............................................................................................ 102
i ii 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 List of Figures Figure 1: Annotated schematic of the Lead Screw design. ............................................................. 2 Figure 2: Annotated schematic of the Belt Drive Concept. ............................................................ 3 Figure 3: Annotated Schematic of the Belt Drive concept indicating operation. ........................... 4 Figure 4: Annotated schematic of the Scissor design. .................................................................... 6 Figure 5: Comparison of baseline, actual, and revised engineering hours in Phase 1, 2, and 3. .. 12 Figure 6: Comparison of baseline, actual, and revised billable engineering hours in Phase 1, 2, and 3. ............................................................................................................................................. 13 List of Tables Table 1: Condensed design decision matrix to evaluate Phase 2 conceptual designs. ................... 8 Table B1 : Outline of concepts generated during brainstorming sessions and Go/No-Go analysis . Table C1 : Outline of analysis for design validity of the Lead Screw concept. ............................. 19 Table D1 : Cost estimate of the Lead Screw design. ...................................................................... 46 Table D2 : Cost estimate of the Belt Drive design. ........................................................................ 47 Table D3 : Cost estimate of the Scissor design. ............................................................................. 48 Table E1 : Outline of analysis for design validity of the Belt Drive concept. ............................... 50 Table F1 : Outline of analysis for design validity of the Scissor concept. .................................... . 75 Table G1 : Summary of revisions to the specification matrix/decision matrix between Phase 1 and Phase 2. ....................................................................................................................................... 101 Word Count in Body: 2296 ........................................................................................................................................................ 16
1 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Introduction Levoroto was approached by Norwood Foundry to design a new crane mounted mold handler for use in their Nisku facility. The existing unit required indexing of the arms to be done manually and ensuring symmetry such that the device was balanced was a tedious task per the operators employed by Norwood. In addition to creating a system that automatically ensures symmetry of the indexing arms, Levoroto must design the mold handler to lift mold boxes up to 1500 lb with lengths varying from 22” to 74”. In order to comply with the existing standard, emphasis was placed on compliance with the specifications in ASME-BTH-1-2017 Design of Under-the-Hook Devices. Levoroto has developed three unique design concepts and recommended the one that best satisfies the project requirements. Concept Description Levoroto engaged in extensive brainstorming and concept evaluation to generate three concepts that could satisfy design requirements. In a meeting with Norwood Foundry, the operators reported that manual rotation was very easy. Thus, making a mechanized rotation system would introduce unnecessary additional costs and points of failure. For this reason, all three concepts use manual rotation of the mold box about the existing trunnions . Norwood’s existing trunnion drawing can be seen in Appendix A. A detailed description of the brainstorming process can be seen in Appendix B. After the initial brainstorming and go/no-go screening, three distinct concepts were developed: The Lead Screw, Belt Drive, and Scissor concepts. Concept 1 - Lead Screw The Lead Screw concept utilizes a custom threaded rod to convert the rotational input from a hand crank to the linear indexing of the mold handler arms. Refer to Figure 1 for a conceptual model of the Lead Screw concept. The threaded rod would feature a right-handed thread on one end and a left-handed thread on the other. This would ensure that the attached arms would translate equally in opposite directions. The mold handler arms will be suspended from a horizontal box beam similar to the existing unit at Norwood. The lead screw will be held by bearings on top of the beam and interface with nuts embedded on the arms to facilitate the linear motion. The hand crank would be geared at a 5:1 ratio, as the threaded rod has five threads per
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2 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 inch, which would make indexing too slow if rotated without a mechanical advantage. A cover would be placed over the lead screw to prevent debris from collecting in the threads and to cover any pinch points. Removable legs would fasten in the ends of the box beam to make the structure free standing for storage. A hook to interface with the crane would be bolted in the center of the box beam. Figure 1: Annotated schematic of the Lead Screw design. Analyses Completed for Lead Screw Design The Lead Screw design was created with ASME-BTH-001 2017 [1] as the primary governing standard. It was determined that the Lead Screw design requires a torque of 2.3 ft lb which can be easily exerted with one hand to rotate and adjust trunnion hooks. The design is free standing with the feet attached and will slide before tipping if struck by a forklift. The maximum bending experienced does not exceed the standard for threaded rods as per ASME B18.31.3 [2]. The following calculations were performed and are shown in Appendix C. ● Box-beam and threaded rod moment/bending analysis ● Lead screw input torque required to overcome steel-steel friction when indexing arms ● Trunnion hook bending stress ● Crane interface hook bending stress
3 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 ● Tipping criteria ● Weld calculation All areas of analysis passed the go/no-go criteria. All required materials and 3 rd party fabricating operations are estimated at $1,300 CAD, within the budget specified by the client ($ 12,000 CAD). Refer to Appendix D for a breakdown of the cost analysis. Concept 2 - Belt Drive The Belt Drive concept uses a timing belt to move the trunnion hooks in opposite directions at the same speed. Refer to Figure 2 and to Figure 3 for conceptual models outlining the Belt Drive design. The mold box is carried by hooks that interface with the trunnions. The structure is built off a box beam similar to the Lead Screw design. The hooks are fastened to collars that slide over the beam element, also similar to the Lead Screw design. The assembly is driven by a manual hand-crank where the belt moves in opposite directions with respect to each side, which correspond to opposite motion of the collars. Figure 2: Annotated schematic of the Belt Drive Concept.
4 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Figure 3: Annotated Schematic of the Belt Drive concept indicating operation. The collars are fastened directly to the belt with a bracket that compresses around the belt. See the magnified “Belt - Collar Bracket Detail” view in Figure 2 for further details. The belt is mounted to pulleys and runs along the length of the beam. When the belt is driven, the front side of the belt’s veloci ty moves towards one end of the beam and the back side of the belt moves toward the other side of the beam at the same magnitude of velocity. One bracket is fastened to the front side of the belt, and the other bracket is fastened to the back side of the belt. This ensures that movement of the collars is equal in magnitude and opposite in direction. The hand crank is located on one end of the structural beam and is connected to the driven pulley of the belt through a pair of bevel gears with a 1:3 gear ratio. This serves the purpose of setting the hand crank’s rotational axis through the long axis of the beam, which ensures that the operator is never between the trunnion hooks. Moreover, the gear reduction corresponds to a torque reduction, which allows lower input torques from the operator to overcome collar friction. An operator must only apply 3.6 lb to the handle to index the sliding collars.
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5 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Analyses Completed for Belt Drive Design The belt driven design is feasible as the required belt tension of 45 lb is below the maximum allowable belt tension of 241 lb meaning that the arms would move before any slippage in the belt system occurred. All bearings and gears that were selected meet the bending and stress requirements per Norton’s Machine Design [3]. It is of note that the belt driven design is built on the same box-beam platform as the lead screw and uses the same trunnion hooks. The calculations for the crane hook and trunnion interfaces, frame bending, welding, and tip/slide calculations are shared between the Lead Screw and Belt Drive concepts. See Appendix E for the following full calculation/analysis specific to Belt Drive design. ● Input torque required to overcome steel-steel collar friction ● Gear force calculations ● Gear stress calculations ● Bearing selection and dynamic load calculations All areas of analysis passed the go/no-go criteria. All required materials and 3 rd party fabricating operations are estimated at $1,600 CAD, within the budget specified by the client ($ 12,000 CAD). Refer to Appendix D for a breakdown of the cost analysis. Concept 3 – Scissor The Scissor concept in Figure 4 uses two arms which index using a hydraulic actuator. Note that electronic components and hydraulic accessories are not present in the model. This is similar to Norwood’s existing Palmer mold hand ler, which was described in the Phase 1 report, except the mold box interface is customized to interact with the trunnions. The cylinder is actuated to extend the arms to fit larger mold boxes. Slowly retracting the piston will bring the device together around the trunnions.
6 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Figure 4: Annotated schematic of the Scissor design. The device is powered through a power cable hanging from the crane. The arms are controlled by a telescoping hydraulic cylinder. Since off-the-shelf cylinders were unable to provide the necessary stroke requirements, the trunnion interface plate is attached onto the lower arms via a clevis pin for further adjustability. This allows the trunnion plate and accommodate the lack of travel of the cylinders in order to fit every mold box size. The trunnion interface plates are cut from a plate of steel and can support the weight of a 1500 lb mold box. The trunnions will rest in the cut-outs of the plates and an operator can manually turn the mold box. The plates also widen the base to allow the assembly to stand freely when not in use. The hydraulic pump is activated through a pendant control box which will allow the operator to control the hydraulic actuator anywhere around the mold handler to provide safer operation. The control panel is equipped with a switch to turn the pump on and off. When the pump is off, a spring in the cylinder retracts the arms with the fluid in the cylinder acting as a damper to slow the return. An emergency switch will also be attached to stop the motion of the cylinder by closing the valve which allows the hydraulic fluid to flow in and out of the cylinder. If no fluid goes in or out, then the cylinder cannot move. Compared to the other concepts, the Scissor concept requires less exertion to operate due to its electronic controls.
7 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Analyses Completed for Scissor Design The scissor design’s vertical and upper arms are built using readily available 4” x 4 hollow structural sections made of A500 steel. Analyses showed that that arms can handle both static loading and the loading of a rotating box held within the trunnion cutouts. This selection of frame dimension and material selection limits the deflection of the arms to be within the CSA S- 16 standard ’ s specification [4]. Critical connections such as the trunnion fitting plate and pin connections also met the minimum design requirements to operate safely as outlined by ASME BTH-001-2017[1]. It was noted that operators need to ensure that Scissor design mold handler is placed on flat ground with a certain height limit and with minimal disturbance in order for the handler not to tip over during storage due to its high center of gravity. See Appendix F for the following full calculation/analysis. ● Deflection/bending analysis of each member when static and when rotating a box ● Minimum dimension requirement for trunnion fitting plate ● Minimum dimension requirement for pin connections ● Tipping criteria All areas of analysis passed the go/no-go criteria with the exception of tipping, however, the geometry can be modified to pass. All required materials and 3 rd party fabricating operations are estimated at $3,500 CAD, within the budget specified by the client ($ 12,000 CAD). Refer to Appendix D for a breakdown of the cost analysis.
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8 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Design Decision Matrix The three designs were evaluated with a design evaluation matrix to see which was most viable. Categories for analysis were taken from the specification matrix defined in the Phase 1 report. Each category was assigned a rank from one to five, with five being critical and one being nice- to-have. Each design was then assigned a score from zero to ten according to how well the design met the specification, with zero meaning the specification was not met, and ten meaning the specification was achieved effectively in terms of cost, simplicity and by exceeding the governing standard. The most effective concept would be the one with the highest overall score. Refer to Table 1 to see a condensed design decision matrix that shows only specifications in which each design scored differently. The complete design decision matrix with all analyzed specifications can be found in Appendix G. Table 1: Condensed design decision matrix to evaluate Phase 2 conceptual designs. Item Description Rank LS BD S Justification 1.0 Functionality - Note the following abbreviations: Lead Screw: LS, Belt Drive: BD, Scissor: S 1.1 Capable of rotating box 180 ° along the long axis 5 8 8 6 LS & BD easily rotate box by hand. Added friction with S makes hand rotation difficult. 1.2 Resistant to dust and debris in dirty foundry 4 7 8 10 LS threads prone to galling from debris but are covered. Belt less prone to galling for BD. All components of S are sealed. 1.3 Mechanical assistance to loosen mold from box 2 0 0 0 No designs incorporated vibrational loosening devices in Phase 2. To be further investigated in Phase 3. 1.4 Can support itself without tipping while stored 4 8 8 6 All designs stand on their own. BD and LS have removable legs and can be stored safely when not in use. However, S is less stable.
9 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Item Description Rank LS BD S Justification 1.6 Indexes length in a symmetric fashion 5 10 8 7 All index symmetrically. LS least prone to slipping. BD could slip or have inequal belt tension. S heavily relies on perfect symmetry of box for operation - which is not present in reality. 1.7 Machine to be designed for infinite life 3 9 7 5 LS has no major components requiring replacement. BD has come wear parts that are inexpensive. S will require replacement of major electronic or hydraulic components during infinite life. 1.8 Can be moved around the foundry with a forklift 1 8 8 3 BD and LS easily lifted with forklift. S does not have a direct interface for forks. 1.10 If a new trunnion is designed, it must be castable by Norwood 5 0 0 0 No designs incorporate new trunnions in phase 2 2.0 Dimensional/Loading 2.9 Machine must not exceed 2000 lb. 5 10 10 8 BD and LS projected to weigh less than 200 lb. S to weigh approximately 450 lb with all components. A penalty of 1 point was imposed for every 200 lb over a minimum weight of 100 lb to prioritize ease of transport for the operators. 2.10 Must interface with a forklift with span of 28" 1 8 8 2 BD and LS easily interface with a forklift, while S can only be carried by one fork which is unsafe. 2.11 If a new trunnion design is used, the new trunnion design must interface with the existing bolt pattern on existing cast boxes 5 0 0 0 All designs interface with the old trunnion 2.12 New trunnion to be cast with ASTM A536 Gr 80-55-6 Ductile Iron 4 0 0 0 All designs interface with the old trunnion
10 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Item Description Rank LS BD S Justification 2.14 Box can easily rotate at min. 10 rpm to ensure all sand dumps out when box has rotated 180° 5 8 8 4 LS and BD use proven design for manual rotation that can rotate at 10 rpm. There is much more friction in S design that makes rotating at 10 rpm manually difficult. 3.0 Safety/Ergonomics 3.4 Indexing collars is controllable in speed for safety 4 9 10 1 LS and BD both index at uniform rate while S retracts with a spring-loaded single acting cylinder in an uncontrolled manner. 3.6 If sharp edges are necessary, there shall be guides to prevent operator injury in place 1 8 8 6 LS and BD have enclosures around pinch points like lead screw, gear, and pulleys. S has no enclosures, but has fewer pinch points.. 3.8 All bolted connections are easily accessible for removal 3 9 9 9 All connections are reasonably accessible. 3.9 All hydraulic/pneumatic hoses and fittings are easily accessible for maintenance 3 10 10 9 LS and BD have no pneumatic or hydraulic components. S components are reasonably accessible. 3.10 Any electric connections and cord cannot be cut or tangled in normal operation 4 10 10 5 BD and LS have no electric components. Pendant cord 3.11 Short enough so an operator can comfortably connect the machine to a crane without a ladder 4 9 9 3 LS and BD are both under 4 ft in height, and can easily be connected to a crane while on the ground. S is more than 6 ft in height when on the ground and difficult to connect. 4.0 Financial Considerations 4.1 Cost of out-of-house components and 3rd party labour not to exceed $12 000 CAD 3 10 10 8 BD costs ~ $1600, LS costs ~$1300, S costs ~$3500. A deduction of 1 point is applied for ever $1000 over a base cost of $2000.
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11 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Item Description Rank LS BD S Justification 4.3 Complexity of BOM 3 9 6 6 LS has fewest parts with only one complex part. BD has more parts that are primarily off the shelf parts. S has few parts, but custom parts and expensive moving parts such as the pump and cylinder. - - Totals 1477 1460 1307 *Note that total scores are taken from the complete design decision matrix. The best design was found to be the Lead Screw concept with a total score of 1477 out of a possible 1710 points. The Belt Drive concept was also viable concept with a score of 1460, and the Scissor concept was the least viable with a score of 1307. In general, the Lead Screw concept was superior due to its safety features, simplicity, reasonably low cost, and reliability while accomplishing the desired functions. Future Work A basic analysis for the purposes of comparison and feasibility of concepts was conducted in this report, however some components require further calculations. A full analysis including detailed drawings will be delivered in the Phase 3 report. Items to be further analyzed are listed below. ● Slide/bind calculations for sliding collar ● Minimum material requirements for trunnion hooks - tensile stress ● Bearing analysis ● Addition of a gear train to increase indexing speed. Requires analysis for shafts and gears ● FEA simulation of critical components under maximum loading ● Stress calculations in Lead Screw threads ● Fatigue analysis of critical components under maximum loading ● Further weld analysis where applicable ● Bolted connection analysis where applicable ● Detailed cost analysis ● Failure mode projections
12 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Project Management Initially Levoroto allocated 205 hours for Phase 2 but an additional 25 hours were required to complete Phase 2. The primary reason for the addition hours was that more analysis than anticipated was required to distinguish the three designs, and thus more calculations with a greater number of iterations were performed. The projected time to complete the analyses was 68 hours, but 96 hours were required. Upon selecting the Lead Screw Design, the schedule for Phase 3 was updated to reflect the list of required future analyses. Refer to Appendix H to see the updated Gantt Chart and to Figure 5 and Figure 6 for a breakdown of baseline, actual, and revised hours and cost for each phase. With the actual hours from Phase 2 and updated schedule for Phase 3, the total hours for the project from start to finish was projected as 588 hours with a total cost of $54,375 which is greater than the initial estimate by $2,235. Figure 5: Comparison of baseline, actual, and revised engineering hours in Phase 1, 2, and 3.
13 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Figure 6: Comparison of baseline, actual, and revised billable engineering hours in Phase 1, 2, and 3. Conclusion Three designs, titled the Lead Screw, Belt Drive, and Scissor concepts, were selected and analyzed during Phase 2 after the initial brainstorming process. Each concept had merits to the design, however, after specification compliance analysis with a design decision matrix, the Lead Screw design was computed to be the best design. It was found to be the most reliable, simplest, and competitive in manufacturing cost while meeting the design specifications. The Lead Screw design shall be further analyzed and refined during Phase 3 with the goal of delivering a complete design package to Norwood Foundry. References [1] ASME BTH-1-2017, Design of Below-the-Hook Lifting Devices. 2017 [2] ASME B18.31.3, Threaded Rods (Inch Series) . 2015. [3] R.L. Norton, Machine Design: An Integrated Approach. 2013 [4] CSA S16:2019 , Design of Steel Structures. 2019 .
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14 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix A - Detailed Drawing of Trunnion A drawing of the trunnion currently used on the mold boxes has been provided by Norwood foundries. The drawing is to be used for informational purposes only and may not be reproduced or shared for commercial gain.
3 4 " 1 3 8 " 3 7 8 " 4 5 8 " 1 3 4 " 3 1 2 " FRONT VIEW SCALE 1 : 1 3 3 4 " 3" 3 3 4 " 5" 1 2 " 3 4 " SIDE VIEW SCALE 1 : 1 11 1 2 " 12" 5" 3 3 4 " TAP FOR 3 8 " HEX BOLT 1" 1" TOP VIEW SCALE 1 : 1 ISOMETRIC VIEW SCALE 1 : 1 DRAWN CHK'D APPV'D MFG Q.A UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN INCHES AS-CAST TOLERANCES: ISO 8062 CT10 FINISH: NAME SIGNATURE DATE MATERIAL: DO NOT SCALE DRAWING REVISION 00 TITLE: DWG NO. SCALE:1:1 SHEET 1 OF 1 A1 ASTM A536 Grade 80-55-06 See specification WEIGHT: 18.4 lb AO 10/11/19 19016 NF Trunnion CROSS REFERENCE NO. DWG NO. PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF NORWOOD FOUNDRY. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF NORWOOD FOUNDRY IS PROHIBITED. A A B B C C D D E E F F G G H H J J K K L L M M 16 16 15 15 14 14 13 13 12 12 11 11 10 10 9 9 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 REVISION NUMBER DATE REVISION REVISION BY CHECKED BY SPECIFICATION: Weight tolerance to be ±5 percent 1. drawing/specification weight. The reference weights can be obtained from average weights based on first articles. All as-cast surfaces shall be smooth and well cleaned by 2. shotblasting. The average surface roughness of as-cast surfaces to be 3. Max. 500 RMS. No excessive grinding marks on the as-cast surfaces are 4. acceptable. As-cast surfaces should be free of major defects 5. including shrinkage, cracks, cold shuts, large cavities, major porosity, or major sand inclusions. All castings to be finished by cutting gating and risering, 6. shotblasting and light grinding. No Painting or coating unless specified by the drawing. 7. Welding repairs or plugging are not allowed. 8.
16 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix B - Brainstorming Process Ideas from brainstorming sessions and reasons for elimination after a Go/No-Go screening are provided in Table B1 below: . Table B1 : Outline of concepts generated during brainstorming sessions and Go/No-Go analysis Concept Description Decision Scissor Folding with a Screw Handle Screw handle in the middle (should be accessible to an operator on the floor) drives scissors - folding mechanism that retract/extend rotating arms while maintaining symmetry and balance. No-Go ● Imposes numerous pinch points along operation line. ● Lots of moving parts which will lead to undesired, frequent maintenance Vertically Moving Linear Actuator Trunnion arms are connected to a linear actuator located at the center and the actuator moves perpendicularly to the arm’s moving direction to equally move them. No-Go ● Requirement to operate within 46” box width range will require a long actuator - which takes up a lot of space during operation. ● Huge bending moments manifest in piston rod at full extension
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17 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Concept Description Decision Slider Crank/Scotch Yoke Rotation motion in the center disk is transferred to linear motion to trunnion hooks. No-Go ● Requirement to operate within 46” box width range will require a large disk - which takes up a lot of space during operation. Belt/Chain Drive Trunnion hooks are connected to belt/chain tread. Go for Belt Drive ● Compact, similar to current equipment ● Go for only belt drive as chain tread inevitably has undesired slack. Chain links may also deflect from gravity due to the horizontal position of the sprockets. Lead Screw Trunnion hooks move with rotating lead screw. Go ● Compact, similar to current equipment ● Intuitive, simple design which requires less complexity than other designs
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18 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Concept Description Decision Scissor Actuated/manual gravity-driven scissors legs come together to get a hold of mold box. Go ● More automated (whether motor/gravity- driven) than other concepts ● Multiple crossing of legs are no-go however because crossing legs have to be long to cover 42” box width range which requires a lot of space during operation. The Lead Screw, Belt Drive, and Scissor concepts were chosen from brainstorming session and have been further developed during Phase 2.
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19 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix C - Lead Screw Concept Calculations Refer to Table C1 for a summary of the calculations conducted to analyze the Lead Screw concept. The calculations are listed in the order that they appear in the report. Table C1 : Outline of analysis for design validity of the Lead Screw concept. Calculation Performed Justification Result Pg # Box-beam and threaded rod moment/bending analysis To ensure the beam does not bend to an extent that would affect the leadscrew Deflection of the lead screw is within ASME B18.31.3 specification for threaded rods and bending stress of beam is acceptable within ASME BTH-1- 2017. 20 Lead screw input torque required to overcome steel-steel friction when indexing arms To ensure a worker can apply the required cranking force to a lever arm to index the lifting arms Cranking force was calculated to be 2.3 lb which is achievable by a worker 2 6 Trunnion hook bending stress To establish a minimum yield strength for the trunnion hooks Greater than 44 ksi yield strength material must be chosen for acceptable geometry . 2 8 Tipping criteria To assess if the assembly with the storage legs will tip if struck with a forklift The assembly will slide before it tips if struck. 3 2 Crane interface hook bending stress To ensure compliance with ASME-BTH-001 2017, and determine the minimum yield strength needed for the hook ring A36 steel will suffice for the given bending stress and safety factor of 3.6 specified by ASME BTH-1-2017. 3 6 Bolted connection analysis on crane hook interface To size bolts in tensile loading to support the crane hook Four 1/2 - 13 UNC bolts will be used 4 1 Weld size analysis on crane hook interface To ensure that parts can be welded together with conventional TIG welding A throat thickness of 3/16" and a minimum bead length of 1.437" is needed and easily achievable. 4 4
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20 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8
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21 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8
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22 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8
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46 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix D - Cost Analysis Unit price, potential supplier, and material estimate are tabulated in Table D1, D2, and D3 respectively for Lead Screw, Belt Drive, and Scissors concepts. See attached quote from Norwood for in-house casting of parts for use in the Scissor design. Table D1 : Cost estimate of the Lead Screw design. Component Description Supplier Part Number Qty Unit Price Comments Total Cost Box Beam Metal Supermarkets HTSQ4250 1 $172 90” length $172 Lead Screw MetalsDepot R21-4140 1 $128 Custom machining required $128 End Bearing Grainger 4ZZR3 2 $32 N/A $64 Midspan Bearing McMaster 5905K137 1 $16 N/A $16 Collar MetalsDepot T141214 1 $63 Two collars to be cut from 1’ length of stock $63 Right Handed Lead Nut Mcmaster 95072A551 1 $58 N/A $58 Left Handed Lead Nut McMaster 95072A551 1 $58 N/A $58 Nut Flange Mcmaster 95082A644 2 $44 N/A $88 Lead Nut Housing MetalDepot P114 1 $20 To be laser cut from steel plate then assembled $20 Crane Hook Interface Custom Part N/A 1 $200 Custom made part $200 Hook Custom Part N/A 1 $150 Made from 1- ¼” square stock $150 Crank Mcmaster 6040K18 1 $52 N/A $52 Bearing Housing MetalDepot A24434 1 $40 Cut from 1’ length of steel 90 degree angle $40 Miscellaneous N/A N/A N/A $150 To account for bolts, lubrication etc. $150 Total $ 1,259
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47 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Table D2 : Cost estimate of the Belt Drive design. Component Description Supplier Part Number Qty Unit Price Comments Total Cost Handle (8'') McMaster 6040K18 1 $118 N/A $118 Metal Bevel Gear (48T) McMaster 2515N15 1 $90 N/A $90 Metal Bevel Pinion (16T) McMaster 2515N16 1 $28 N/A $28 12mm Thrust bearing SKF 51101 2 $25 N/A $50 15mm Thrust Bearing SKF 51102 2 $30 N/A $60 Four bolt flange bearing McMaster 6494K32 4 $34 N/A $139 H Series Pulley McMaster 6495K470 2 $79 N/A $159 H Series Belt McMaster 6484K728 2 $100 Comes in 100'' each. Cut to length for 191.7'' $200 Collar and Clamp Custom Part N/A 2 $50 Custom part with no specific tolerances needed $100 Belt Tensioner McMaster 60225K14 2 $128 N/A $256 Beam MetalDepot T16438 1 $327 Cut to 100 inches or 8.33 feet $327 Gear box frame Custom Part 1 $20 Custom part with no specific tolerances needed $20 Flange Frame Custom Part 2 $20 Custom part with no specific tolerances needed $40 Total $ 1,588
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48 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Table D3 : Cost estimate of the Scissor design. Component Description Supplier Part Number Qty Unit Price Comments Total Cost Trunnion Holder McMaster 1388K563 1 $389 N/A $389 Pin for connection between Trunnion Holder and Vertical Arm McMaster 98306A904 2 $7 N/A $14 Vertical Arms Metals Depot T14412 2 $98 N/A $196 Pin for connection between Vertical Arm and Upper Arm McMaster 98306A852 1 $30 N/A $30 Upper arms Metals Depot T14412 2 $92 N/A $184 Pin for crane connection McMaster 98306A677 1 $54 N/A $54 Crane shackle McMaster 8966T54 1 $101 N/A $101 Small/Large Bracket McMaster 8910K542 1 $14 N/A $14 Hydraulic Cylinder Southern Hydraulic Cylinder Inc. 3243CT 1 $885 N/A $885 Hydraulic Hose McMaster 2916T4 1 $217 N/A $217 Hydraulic Pressure Gauge McMaster 38055K21 1 $49 N/A $49 Hydraulic Power Unit McMaster 3973K41 1 $967 N/A $967 Customized Mold for Both 1- and 2- pin Connections See Attached Quote from Norwood - 1 $461 Custom part $461 Total $3,561
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50 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix E - Belt Drive Concept Calculations Refer to Table E1 for a summary of the calculations conducted to analyze the Belt Drive concept. The calculations are listed in the order that they appear in the report. Table E1 : Outline of analysis for design validity of the Belt Drive concept. Calculation Performed Justification Result Pg # Belt Tension To determine the minimum belt tension required to move the collars. Knowing the collar and hook weights, along with the kinetic coefficient of friction, the required belt tension was calculated as 200 N or 45 lb which is below the allowable maximum belt tension of 1070 N or 241 lb 52 Gear Forces and Torques To determine gear forces and torques developed from the belt and pulley for further gear stresses and bearing selection analysis. Calculated gear forces and torques were used to further analyze stress and FOS in later calculations. 55 Worst Case Hand Force Important to know because the operators should not have to exert large forces on hand crank to drive the belt. Required crank force to overcome collar friction was calculated as 16 N or 3.6 lb which can be applied by one hand. 55 Bending and Contact Stress To determine stresses in gears and the critical component in the gear train. It was shown that pinion gears will be the most critical component with the lowest safety factor of 2.1. 60
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51 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Calculation Performed Justification Result Pg # Dynamic Load Rating To select a bearing that satisfies both the forces and the life revolutions expected. By considering the gear forces on each shaft and the bearing positions along it, the reaction forces were determined. Two SKF 51101 and two SKF 51102 thrust bearings were located at pinion and bevel shaft respectively which specifies a higher load rating than required. 6 8 The following calculations have been performed in Appendix B for the Lead Screw design. The Belt Drive concept shares some identical geometry and loading conditions with the Lead Screw, and thus the calculations were not duplicated for brevity. Refer to Appendix B for complete details. ● Box-beam moment/bending analysis ● Trunnion hook bending stress ● Crane hook interface bending stress ● Tipping criteria ● Weld size analysis on crane hook interface ● Bolted connection analysis on crane hook interface
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75 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix F - Scissor Concept Calculations The following calculations have been performed and are listed in order of appearance. Table F1 . Table F1 : Outline of analysis for design validity of the Scissor concept. Calculation Performed Justification Result Pg # Deflection/bending analysis of each member when static and when rotating a box To ensure the main arm frame made of hollow structural section does not bend to an extent that would deviate from CSA-S16 During static condition and rotation of the heav iest box with 68” width, both upper and lower arms experience deflection less than L/600 specified by CSA standard, hence 4”x4”x0.25” HSS are sufficient for Scissor mold handler. 7 6 Minimum dimension requirement for trunnion fitting plate To ensure that trunnion fitting plate’s dimensions (width and thickness) will not yield under the given loading conditions With a safety factor of 3.6 as per ASME-BTH standard, trunnion fitting plate with minimum thickness of 0.0036” and distance of 3.75” between hole end and material end is feasible during static condition. 8 7 Minimum dimension requirement for pin connections To ensure that pinholes will not fail with the heaviest box loading Pin hold made of 4140 steel with thickness of 0.5” will be sufficient to hold the loading through 1” diameter pin. Assuming the worst case of tight fit between pin and pinhole, the pinhole will not fail. 90 Tipping criteria To ensure that the Scissor design can be stored safely without tipping If a force of 248 lb is applied onto the handler higher than 10.5”, the mold handler will tip over. 93
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97 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix G – Design Decision Matrix A design decision matrix based on the specification matrix from Phase 1 was used to evaluate the validity of each conceptual design. The complete matrix with scores assigned to each concept can be seen below. Certain items were changed from Phase 1 to convey the design intern more clearly. Refer to Table G1 for a list of changes between Phase 1 and Phase 2.
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Item Description Rank LS BD S Justification 1.0 Functionality ° Note the following abbreviations± Lead Screw± LS² Belt Drive± BD² Scissor± S ³´³ Capable of rotating box ³µ¶ ° along the long axis · µ µ ¸ LS ¹ BD easily rotate box by hand´ Added friction with S makes hand rotation difficult´ ³´º Resistant to dust and debris in dirty foundry » ¼ µ ³¶ LS threads prone to galling from debris but are covered´ Belt less prone to galling for BD´ All components of S are sealed´ ³´½ Mechanical assistance to loosen mold from box º No designs incorporated vibrational loosening devices in Phase º´ To be further investigated in Phase ½´ ³´» Can support itself without tipping while stored » µ µ ¸ All designs stand on their own´ BD and LS have removable legs and can be stored safely when not in use´ However² S is less stable´ ³´· Operates in temperature range from ³¶°C to »¶°C » ³¶ ³¶ ³¶ All designs can operate in this temperature range´ ³´¸ Indexes length in a symmetric fashion · ³¶ µ ¼ All index symmetrically´ LS least prone to slipping´ BD could slip or have inequal belt tension´ S heavily relies on perfect symmetry of box for operation ° which is not present in reality´ ³´¼ Machine to be designed for infinite life ½ ¾ ¼ · LS has no major components requiring replacement´ BD has come wear parts that are inexpensive´ S will require replacement of major electronic or hydraulic components during infinite life´ ³´µ Can be moved around the foundry with a forklift ³ µ µ ½ BD and LS easily lifted with forklift´ S does not have a direct interface for forks´ ³´¾ If existing trunnions used² machine interfaces with existing trunnions described below º ³¶ ³¶ ³¶ All designs interface with existing trunnions´ ³´³¶ If a new trunnion is designed² it must be castable by Norwood · No designs incorporate new trunnions in phase º 2.0 Dimensional/Loading º´³ Capable of lifting sand bold box up to ³·¶¶ lb · ³¶ ³¶ ³¶ All three designs rated to lift ³·¶¶ lb box´ º´º Capable of lifting a box of length ¼»¿ · ³¶ ³¶ ³¶ All three can fit ¼»¿ long box º´½ Capable of lifting a box of length ºº¿ · ³¶ ³¶ ³¶ All three can fit ¼»¿ long bºº º´» Machine°Box interface must fit around trunnion with a ½´¼·¿ OD flare at the end º ³¶ ³¶ ³¶ All three designs acommodate these dimensions´ º´· Machine°Box interface must contact with trunnion of º´·¶¿ OD º ³¶ ³¶ ³¶ All three designs acommodate these dimensions´ º´¸ Min OD of º´·¶¿ on trunnion is º¿ in length between flared ends º ³¶ ³¶ ³¶ All three designs acommodate these dimensions´ º´¼ Machine must couple with two ton crane hook with ID of º°³À»¿ · ³¶ ³¶ ³¶ All three designs acommodate these dimensions´ º´µ Machine°Crane interface must fit through a gap of ³°¼À³¸¿ · ³¶ ³¶ ³¶ All three designs acommodate these dimensions´ º´¾ Machine must not exceed º¶¶¶ lb´ · ³¶ ³¶ µ BD and LS projected to weigh less than º¶¶ lb´ S to weigh approximately »·¶ lb with all components´ A penalty of ³ point was imposed for every º¶¶ lb over a minimum weight of ³¶¶ lb to prioritize ease of transport for the operators´ º´³¶ Must interface with a forklift with span of ºµ¿ ³ µ µ º BD and LS easily interface with a forklift² while S can only be carried by one fork which is unsafe´ º´³³ If a new trunnion design is used² the new trunnion design must interface with the existing bolt pattern on existing cast boxes · All designs interface with the old trunnion º´³º New trunnion to be cast with ASTM A·½¸ Gr µ¶° ··°¸ Ductile Iron » All designs interface with the old trunnion º´³½ Safety factor to be governed by ASME BTH°³° º¶³¼ · ³¶ ³¶ ³¶ All designs follow ASME BTH°³°º¶³¼ guidelines 9 8
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Item Description Rank LS BD S Justification Ï" *(*RQWLQXQRXV QRLVH OHYHOV JHQHUKWHG E\ GHYLFH ÐLQFOXGLQJ KOKUPÑ PXVW QRW H[FHHG # G)')(&( ÒÓ ÒÓ ÒÓ (&(OO GHVLJQV VKKOO FRPSO\Ï Ô Ô Totals 1477 1460 1307 100
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101 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Table G1 : Summary of revisions to the specification matrix/decision matrix between Phase 1 and Phase 2. Section Former Description Revised Description Justification 1.7 Machine should last for a minimum of 50 years with no refabrication or replacement of major components Machine to be designed for infinite life Change to "design for infinite life" as per the grader's feedback on the Phase I report. 2.11 N/A If a new trunnion design is used, the new trunnion design must interface with the existing bolt pattern on existing cast boxes Trunnion redesign was deemed out of the scope of this project 2.14 Box rotates quickly enough that loose sand does not fall out prematurely (10-20 RPM) Box can easily rotate at min. 10 rpm to ensure all sand dumps out when box has rotated 180° To add clarity about the purpose for a fast box rotation 3.4 Indexes length slowly enough to be precise and safe Indexing collars is controllable in speed for safety To add clarity about what defines safe, such as having speed control 3.6 No sharp edges to be used in the design If sharp edges are necessary, there shall be guides to prevent operator injury in place To not hamstring the design out of being able to use sharp edged objects 4.3 N/A Complexity of BOM An influential factor not considered in the original design specification matrix 5.8 If the handler is deemed "Category B" (worst case), design/safety factors for the handler shall be not less than 3.00 for limit states of yielding or buckling and 3.60 for limit states of fracture and for connection design. N/A Removed because this point was already covered in item 2.13
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102 9211 – 116 St NW Mechanical Engineering Building Edmonton, AB T6G 2G8 Appendix H – Updated Gantt Chart The Gantt chart that was initially outlined in Phase 1 has been updated to reflect the actual schedule in Phase 2 and changes for Phase 3.
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2019-09-07 2019-09-08 2019-09-09 2019-09-10 2019-09-11 2019-09-12 2019-09-13 2019-09-14 2019-09-15 2019-09-16 2019-09-17 2019-09-18 2019-09-19 2019-09-20 2019-09-21 2019-09-22 2019-09-23 2019-09-24 2019-09-25 2019-09-26 2019-09-27 2019-09-28 2019-09-29 2019-09-30 2019-10-01 2019-10-02 2019-10-03 2019-10-04 2019-10-05 2019-10-06 2019-10-07 2019-10-08 2019-10-09 2019-10-10 2019-10-11 2019-10-12 2019-10-13 2019-10-14 2019-10-15 2019-10-16 2019-10-17 2019-10-18 2019-10-19 2019-10-20 2019-10-21 2019-10-22 2019-10-23 2019-10-24 2019-10-25 2019-10-26 2019-10-27 2019-10-28 2019-10-29 2019-10-30 2019-10-31 MAJOR MILESTONES Phase 1 Report 100% 115 111 2019-09-11 2019-09-30 20 Days 2019-09-11 2019-09-30 20 Days Phase 2 Report 100% 205 230 2019-09-30 2019-11-04 36 Days 2019-10-02 2019-11-04 34 Days Phase 3 Report 0% 226 2019-12-02 2019-12-02 1 Days Final Design Conference Poster/Presentation 0% 39 2019-12-06 2019-12-06 1 Days PHASE 2 TASKS Follow Up with Client on Phase 1 Report 100% 1 1 2019-09-30 2019-10-01 2 Days 2019-10-02 2019-10-03 2 Days Brainstorm Session 100% 12 18 2019-09-30 2019-10-03 4 Days 2019-09-30 2019-10-02 3 Days Conceptual Designs Solid Modeling Concept 1 (Lead Screw) 100% 5 8 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-05 3 Days Concept 2 (Belt Driven) 100% 5 9 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-20 18 Days Concept 3 (Scissors Type) 100% 5 11 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-23 21 Days Conceptual Designs Calculations Concept 1 (Lead Screw) 100% 22 21 2019-10-03 2019-10-18 16 Days 2019-10-04 2019-10-25 22 Days Concept 2 (Belt Driven) 100% 22 35 2019-10-03 2019-10-18 16 Days 2019-10-09 2019-10-25 17 Days Concept 3 (Scissors Type) 100% 24 40 2019-10-03 2019-10-18 16 Days 2019-10-09 2019-10-27 19 Days Cost Analysis Concept 1 (Lead Screw) 100% 4 3 2019-10-09 2019-10-18 10 Days 2019-10-09 2019-10-25 17 Days Concept 2 (Belt Driven) 100% 4 3 2019-10-09 2019-10-18 10 Days 2019-10-07 2019-10-25 19 Days Concept 3 (Scissors Type) 100% 4 4 2019-10-09 2019-10-18 10 Days 2019-10-09 2019-10-28 20 Days Design Evaluation Matrix 100% 12 9 2019-10-16 2019-10-17 2 Days 2019-10-23 2019-10-29 7 Days Report Writing and Formatting 100% 56 50 2019-10-07 2019-11-04 29 Days 2019-10-16 2019-11-04 20 Days Weekly Meetings with Advisor 100% 30 18 2019-10-02 2019-10-23 22 Days 2019-10-02 2019-10-23 22 Days Report Submission 100% 0 0 2019-11-04 2019-11-04 1 Days 2019-11-04 2019-11-04 1 Days Team Assessment 100% 0 0 2019-11-07 2019-11-08 2 Days PHASE 3 TASKS Follow Up with Client on Phase 2 Report 0% 1 2019-11-04 2019-11-05 2 Days Project Review Meeting with Dr. Duke 0% 6 2019-11-06 2019-11-06 1 Days Detailed Design Calculations Detailed Connection Calculation Inc. Bearings, Bolts 0% 10 2019-11-06 2019-11-15 10 Days Gear Train Design 0% 10 2019-11-06 2019-11-15 10 Days Slide/Bind Calculation for Sliding Collar 0% 10 2019-11-06 2019-11-11 6 Days FEA on Critical Components Incl. Mold Box Arm 0% 30 2019-11-06 2019-11-20 15 Days Trunnion Hook Requirements 0% 10 2019-11-06 2019-11-15 10 Days Fatigue Calculation 0% 20 2019-11-06 2019-11-20 15 Days Brief Analysis of New Trunnion/Rotation Mechanism 0% 20 2019-11-06 2019-11-20 15 Days Risk/Safety Analysis 0% 6 2019-11-21 2019-11-23 3 Days Detailed Cost Analysis 0% 4 2019-11-13 2019-11-20 8 Days Final Drawing Package 0% 20 2019-11-04 2019-11-20 17 Days Consensus on Design Spec Matrix with Client 0% 1 2019-11-21 2019-11-23 3 Days Report Writing and Formatting 0% 60 2019-11-04 2019-12-02 29 Days Weekly Meetings with Advisor 0% 18 2019-11-06 2019-11-27 22 Days Report Submission 0% 0 2019-12-02 2019-12-02 1 Days FINAL DESIGN CONFERENCE POSETER/PRESENTATION Poster Design 0% 9 2019-11-30 2019-12-03 4 Days Preparation for Presentation 0% 12 2019-12-02 2019-12-06 5 Days Presentation/Poster Display 0% 18 2019-12-06 2019-12-06 1 Days Team Assessment 0% 0 2019-12-06 2019-12-08 3 Days ACTUAL HOURS Oct-19 Sep-19 ACTUAL START DATE ACTUAL END DATE ACTUAL DURATION RESPONSIBLE PROGRESS FORECAST DURATION FORECAST END DATE FORECAST START DATE PROJECTED HOURS 103
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2019-11-01 2019-11-02 2019-11-03 2019-11-04 2019-11-05 2019-11-06 2019-11-07 2019-11-08 2019-11-09 2019-11-10 2019-11-11 2019-11-12 2019-11-13 2019-11-14 2019-11-15 2019-11-16 2019-11-17 2019-11-18 2019-11-19 2019-11-20 2019-11-21 2019-11-22 2019-11-23 2019-11-24 2019-11-25 2019-11-26 2019-11-27 2019-11-28 2019-11-29 2019-11-30 2019-12-01 2019-12-02 2019-12-03 2019-12-04 2019-12-05 2019-12-06 MAJOR MILESTONES Phase 1 Report 100% 115 111 2019-09-11 2019-09-30 20 Days 2019-09-11 2019-09-30 20 Days Phase 2 Report 100% 205 230 2019-09-30 2019-11-04 36 Days 2019-10-02 2019-11-04 34 Days Phase 3 Report 0% 226 2019-12-02 2019-12-02 1 Days Final Design Conference Poster/Presentation 0% 39 2019-12-06 2019-12-06 1 Days PHASE 2 TASKS Follow Up with Client on Phase 1 Report 100% 1 1 2019-09-30 2019-10-01 2 Days 2019-10-02 2019-10-03 2 Days Brainstorm Session 100% 12 18 2019-09-30 2019-10-03 4 Days 2019-09-30 2019-10-02 3 Days Conceptual Designs Solid Modeling Concept 1 (Lead Screw) 100% 5 8 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-05 3 Days Concept 2 (Belt Driven) 100% 5 9 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-20 18 Days Concept 3 (Scissors Type) 100% 5 11 2019-10-03 2019-10-18 16 Days 2019-10-03 2019-10-23 21 Days Conceptual Designs Calculations Concept 1 (Lead Screw) 100% 22 21 2019-10-03 2019-10-18 16 Days 2019-10-04 2019-10-25 22 Days Concept 2 (Belt Driven) 100% 22 35 2019-10-03 2019-10-18 16 Days 2019-10-09 2019-10-25 17 Days Concept 3 (Scissors Type) 100% 24 40 2019-10-03 2019-10-18 16 Days 2019-10-09 2019-10-27 19 Days Cost Analysis Concept 1 (Lead Screw) 100% 4 3 2019-10-09 2019-10-18 10 Days 2019-10-09 2019-10-25 17 Days Concept 2 (Belt Driven) 100% 4 3 2019-10-09 2019-10-18 10 Days 2019-10-07 2019-10-25 19 Days Concept 3 (Scissors Type) 100% 4 4 2019-10-09 2019-10-18 10 Days 2019-10-09 2019-10-28 20 Days Design Evaluation Matrix 100% 12 9 2019-10-16 2019-10-17 2 Days 2019-10-23 2019-10-29 7 Days Report Writing and Formatting 100% 56 50 2019-10-07 2019-11-04 29 Days 2019-10-16 2019-11-04 20 Days Weekly Meetings with Advisor 100% 30 18 2019-10-02 2019-10-23 22 Days 2019-10-02 2019-10-23 22 Days Report Submission 100% 0 0 2019-11-04 2019-11-04 1 Days 2019-11-04 2019-11-04 1 Days Team Assessment 100% 0 0 2019-11-07 2019-11-08 2 Days PHASE 3 TASKS Follow Up with Client on Phase 2 Report 0% 1 2019-11-04 2019-11-05 2 Days Project Review Meeting with Dr. Duke 0% 6 2019-11-06 2019-11-06 1 Days Detailed Design Calculations Detailed Connection Calculation Inc. Bearings, Bolts 0% 10 2019-11-06 2019-11-15 10 Days Gear Train Design 0% 10 2019-11-06 2019-11-15 10 Days Slide/Bind Calculation for Sliding Collar 0% 10 2019-11-06 2019-11-11 6 Days FEA on Critical Components Incl. Mold Box Arm 0% 30 2019-11-06 2019-11-20 15 Days Trunnion Hook Requirements 0% 10 2019-11-06 2019-11-15 10 Days Fatigue Calculation 0% 20 2019-11-06 2019-11-20 15 Days Brief Analysis of New Trunnion/Rotation Mechanism 0% 20 2019-11-06 2019-11-20 15 Days Risk/Safety Analysis 0% 6 2019-11-21 2019-11-23 3 Days Detailed Cost Analysis 0% 4 2019-11-13 2019-11-20 8 Days Final Drawing Package 0% 20 2019-11-04 2019-11-20 17 Days Consensus on Design Spec Matrix with Client 0% 1 2019-11-21 2019-11-23 3 Days Report Writing and Formatting 0% 60 2019-11-04 2019-12-02 29 Days Weekly Meetings with Advisor 0% 18 2019-11-06 2019-11-27 22 Days Report Submission 0% 0 2019-12-02 2019-12-02 1 Days FINAL DESIGN CONFERENCE POSETER/PRESENTATION Poster Design 0% 9 2019-11-30 2019-12-03 4 Days Preparation for Presentation 0% 12 2019-12-02 2019-12-06 5 Days Presentation/Poster Display All 0% 18 2019-12-06 2019-12-06 1 Days Team Assessment All 0% 0 2019-12-06 2019-12-08 3 Days ACTUAL HOURS Dec-19 Nov-19 ACTUAL START DATE ACTUAL END DATE ACTUAL DURATION RESPONSIBLE PROGRESS FORECAST DURATION FORECAST END DATE FORECAST START DATE PROJECTED HOURS 104
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d) A common process for the assembly of compound cylinders is thermal shrink- fitting. In your own words, Describe briefly how this procedure may be performed. Explain with reference to solid mechanics concepts, how a thermal shrink-fit can generate forces which hold the cylinders together and enable higher pressure bearing capability (in comparison to a single cylinder). Considering the concepts/principles explained above, describe more generally an alternative method for achieving such improved performance and describe advantages/disadvantages, if any, over a thermal shrink-fitting procedure. (200 - 300 words).
3-The forces developed during a conventional cementing operation. /B/Data given as: Casing dimensions(20-in OD, 18.730-in ID,133lbm/ft).(26-in) Hole size.(350 ft) casing setting depth. Mud weight(8.7 ppg). fr Cement properties: Cement H API class with(4%) bentonite. Slurry weight(14.2 ppg, 106 lbm/ft³). Slurry yield(1.5 ft³/sack). Water requirements(7.6 gal/sack).Pumping rate through drillpipe(100 gal/min) and through casing(300 gal/min). Drillpipe (5-in OD, 4.276-in ID,19.5 lb/ft). Allow(15 min) for release of plugs. A shoe truck(80 ft) and allow 100% excess cement in the open hole. Assume casing to be cemented to surface. Calculate: 1-The required quantities of cement and bentonite. (1-2) Scanned by CamScanner 2-Volume of mixing water. 4-Will the casing float?
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