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Team FOAMDesign Team 6

Members:Fredrik Sy, Dainis Nams, Allison Chua, Motaz Taha

Advisor: Dr. Darrel DomanClient: Precise Designs Engineering Solutions

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Contents Background Requirements Final Design Testing Final Product Requirements Check Conclusions Future Work Acknowledgments

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Background

Client’s production requires foam profile cutting

Current method is water jet cutting: Outsourced Long drying time

Client wants to cut foam using in house machine shop

Polyplank foam (www.casecad.com)

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Requirements

Essential Requirements Important RequirementsSafety Budget : $3000Interface with CNC machine Ease of installation and

detachmentArbitrary pocket profiles Acceptable cut speed1/4 in. minimum hole dimension

Cut tolerance of 1/32 in.

Cut depth of 4.75 in. Body overall length less than 6 in.

Acceptable cut qualityMinimal need for cleaning or replacing parts

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Design Overview Design divided into subsystems:

Cutting element Cutting element holder Rotational power transfer Body and CAT40 mounting Temperature control

Five Subsystems

Body And CAT40 Mounting

Rotational Power Transfer

Cutting Element

Cutting Element Holder

Temperature Control

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Final Design

Collet Holder

Bracket Attachment And Plugin

Slip Ring

Cutting Element

CAT40 HeadCNC Head Bracket

Slip Ring Attachment

Power Jack

Conical Pin

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Final Design

CNC Head Bracket

Slip Ring

Cutting Element

CAT40 Head

Wiring Terminal

Power PluginAnd Slip Ring Bracket Attachment

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Temperature Control Custom fabricated on-off control

Uses thermocouple signal to modulate power to resistive element

Toggles around set temperature (±10°C) Adjustable set temperature

Temperature Control

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Testing Goals Determine a measure for quantifying cut quality Cut quality was measured as a function of:

Feed speed Temperature

Determine minimum wall thickness of cut foam Determine ability to interface with CNC machine Determine cut tolerances and minimum hole dimension

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Qualitative scale to measure quality of cuts

Quality Index

(1) (2)

(3) (4)

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Performance Testing Single Axis Foam

Feeder Temperature tests Feed speed tests Long deep cut tests

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Performance Results: CNC Interface CNC interface Automatic tool changer

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Performance Results: CNC Foam Cutting

Cut direction determines quality One side has good quality

Milling: spiral outwards 50% overlap, 1/8 in. increments

Minimum wall thickness of 0.5 in. Variable depth pockets

Tool PathCutting Increment

Remaining Foam

Pocket

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CNC Foam Cutting Pocket created for 3 way solenoid valve Pocket has 3 depth levels

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CNC Foam Cutting Video

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CNC Foam Cutting: Example Product

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Operational Parameters

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Requirements Check

Essential Requirements Important RequirementsSafety Budget : $3000Interface with CNC machine Ease of installation and

detachmentArbitrary pocket profiles Acceptable cut speed1/4 in. minimum hole dimension

Cut tolerance of 1/32 in.

Cut depth of 4.75 in. Body overall length less than 6 in.

Acceptable cut quality Automatic tool changer interface

Minimal need for cleaning or replacing parts

Variable depth pockets

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Cut Tolerance Mostly acceptable cut tolerance (1/32 in. )

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Conclusions Alternative method to water jet cutting developed Final design constructed Final design tested Operational parameters of foam cutting tool determined Project requirements exceeded

Automatic tool changer Variable depth pockets

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Future Refinements Purchase slip ring with higher RPM Construct a variety of cutter sizes and shapes

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Acknowledgements Project Supervisor: Dr. Darrel Doman Design Project Course Coordinators: Dr. Andrew Warkentin And Dr. Julio

Militzer Client: Precise Designs Engineering Solutions Shell ROV Team Dalhousie Staff

Angus MacPherson Jon MacDonald Albert Murphy Mark MacDonald Ray Newman Rob Warner

SolidWorks

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Safety Regulations (1) Purpose: The purpose of this document is to outline the safety procedures to be followed for any testing

to be done in the TEAM FOAM project and specifies the responsibilities of the individuals performing said testing or experiment. The document also outlines requirements in the procedures of these experiments and testing.

General Safety Procedure: This section applies to all testing. Any testing done with heating elements, electrical devices or

any device that may bring bodily harm requires the presence of at least two people performing the experiment. Each person is responsible for both himself/herself and for every other person performing the testing to abide by the safety procedure outlined in this document.

Should one person be injured or incapacitated, it is the responsibility of the all the members performing the test to ensure that immediate and proper treatment be applied

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Safety Regulations (2) Heating elements: This section pertains to all testing done with any heating elements. The following safety

equipment/procedures must be used: Safety Glasses Gloves with thermal insulation sufficient for the temperatures of the experiment No open toe footwear The heating element must be at least 5 feet away from any easily combustible fuel The heating element must not rest or be held in place with chance of heating element igniting

any object.

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Safety Regulations (3) Electrical power supplies: This section pertains to constructing electrical circuitry or mechanism that convey/interact in

some way that are not inherently electrically insulated. The following safety equipment/procedures must be used:

Safety Glasses Gloves with electrical insulation The electrical equipment must be at least 5 feet away from any easily combustible fuel so as to

avoid the chance that a spark ignites the fuel. The testing mechanism must be designed such that the mechanism cannot draw power unless

the person using the mechanism is not at least 3 feet away from the equipment.

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BudgetINCOME VALUE

Requested support from Dalhousie University, Mechanical Engineering $ 200.00 Requested support from Precise Designs $ 3,000.00 Total income $ 3,200.00 EXPENSES QUANTITY UNIT PRICE TOTAL PRICE SUPPLIERPrototype supplies 1/16 in. diameter spring steel rod 1 $ 3.00 $ 3.00 Maritime Hobbies & Crafts Knife 1 $ 3.00 $ 3.00 Buck and Near Dollar Store Motor 1 $ 10.00 Princess Auto Muffler tape 1 $ 6.00 $ 6.00 Canadian Tire Oven element 2 $ - $ - Team member Switch 1 $ 3.00 $ 3.00 Princess AutoFinal design suppliesSubsystem 1: Cutting element 1/4 in. stainless steel tube 6 X 12" $ 16.50 $ 16.50 Hobbylinc.com 20 gauge Nichrome 80 resistance wire with double glass insulation 1 X 50' $ 34.00 $ 34.00 Pelican Wire Co., Inc. 6 in. 2-Way cross-slide vice, product #8128159 1 $ 99.00 $ 99.00 Princess AutoSubsystem 2: Cutting element holder ER-20 collet chuck, 3/16 in. 1 $ 20.00 $ 20.00 Royal Product ER-20 collet chuck, 1/4 in. 1 $ 20.00 $ 20.00 Royal Product ER-20 collet chuck, 1/2 in. 1 $ 20.00 $ 20.00 Royal ProductSubsystem 3: Rotational power transfer Slipring, model AC4598-6 1 $ 384.48 $ 384.48 Moog Components Group Variac, model 6994K24 1 $ 368.09 $ 368.09 McMaster-CarrSubsystem 4: Body and CAT40 mounting ER-20 CAT40 collet chuck holder 1 $ 180.00 $ 180.00 Royal ProductOther (i.e. wiring, hardware, bearings) - $ 300.00 $ 300.00 Various

Technician time from Dalhousie University N/A $ - $ - Dalhousie UniversityTechnican time from Precise Designs N/A $ - $ - Precise DesignPaperwork costs (i.e. printing, faxing) N/A $ 50.00 $ 50.00 VariousShipping (estimated) N/A $ 50.00 $ 50.00 VariousTax (15%) N/A $ 233.56 $ 235.06 N/AContingency fund (20%) N/A $ 358.13 $ 360.43 N/A

Total expenses $ 2,162.56 N/A EQUITY BALANCE

$ 1,037.44

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Construction Of Cutting Element

Connection Wires To Slip Ring

Thermocouple Wires

Resistance Wires Steel Tube

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Detailed Design Parameters Budget : Spent $ 1 900

Under budget by ~ $1 300 Overall length ( to beginning of element) is 4.25 in.