Team Tie-Master Brittany Ballard Cam Leslie Steve May Tie-down
Finishing Machine
Slide 2
Current Situation: Surface of aluminum tracks finished by-hand
Burrs on edges from milling Chips from milling can get lodged in
the channel of the track Outer surface of the track is inconsistent
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 3
Current Issues: Manual surface finish is time consuming May
pose health hazards Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
Slide 4
Design, fabricate, and test a machine that will automatically
finish, de-burr, and clear debris from several different tie-down
track profiles Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
Slide 5
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 6
Conceptual Design Broken into specific areas: Creating the
Grain and De-burring Removing Debris Track Movement Project Problem
Project Goal Specifications Conceptual Design Detailed Design
Manufacturing Processes Final Product Cost Future Adaptations Q
& A
Slide 7
Creating the Grain and De-burring Project Problem Project Goal
Specifications Conceptual Design Detailed Design Manufacturing
Processes Final Product Cost Future Adaptations Q & A
Slide 8
Stresses were calculated w/ various increasing loads until
failure predicted at 300 lbf. FEA with ABAQUS Project Problem
Project Goal Specifications Conceptual Design Detailed Design
Manufacturing Processes Final Product Cost Future Adaptations Q
& A
Slide 9
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 10
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 11
This is the final design. The overall length is 4ft. The case
footprint is 14.5x14 Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
Slide 12
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 13
Milling and welding were the two processes most used for this
project Many parts were ordered from manufacturers This will allow
for easy replacement Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
Slide 14
Project Problem Project Goal Specifications Conceptual Design
Detailed Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 15
Systems were tested separately Each system met specs when
tested separately Systems are currently being integrated Project
Problem Project Goal Specifications Conceptual Design Detailed
Design Manufacturing Processes Final Product Cost Future
Adaptations Q & A
Slide 16
ItemCost Testing Materials$ 300 Materials for Prototypes$ 100
Materials for Final Product$ 1,500 Machine Shop
Infrastructure$1,000 Travel Expenses$ 450 Other Materials$ 150
Total cost $ 3,500 Initial Budget of $ 4,000 Project Problem
Project Goal Specifications Conceptual Design Detailed Design
Manufacturing Processes Final Product Cost Future Adaptations Q
& A
Slide 17
Using the current setup, there are 2-6 pads and 4-5.6 pads in
the finishing wheel stack Cost of each pad is $2.58 ea The pad
stack can be used for approximately 200 ft of track, depending on
the length of individual tracks Media cost = $15.48 for 200 ft of
track = $0.08 per ft of track Project Problem Project Goal
Specifications Conceptual Design Detailed Design Manufacturing
Processes Final Product Cost Future Adaptations Q & A
Slide 18
Work DescriptionDuration Conceptual and Detailed Design432 Hrs
Testing75 Hrs Machine Shop (Fabrication)375 Hrs Computer-Aided
Design30 Hrs Paperwork60 Hrs TOTAL972 Hrs These hours include time
for all group members (3) This equates to approximately 15.5 hrs of
work per week, per person on this project
Slide 19
Kaizen Projects Make finishing pads last longer Layout of Macs
shop Other Features Adding a debris separator to funnel Future use
on other aluminum parts Change placement of finishing pads for
improved grain Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
Slide 20
Questions? Project Problem Project Goal Specifications
Conceptual Design Detailed Design Manufacturing Processes Final
Product Cost Future Adaptations Q & A
