P16665: Gleason Hobbing Machine Force Applicator
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Detailed Design

Table of Contents

Background Information

Quick Project Overview

Problem Definition

Hobbing is the machining process for gear cutting, where the cutting edge and work piece turn simultaneously in a machine to create a specific gear design. Gleason Works is one of the leaders in the hobbing business and has asked our team to help develop a solution to one of their problems. If the machine is not stiff enough between the cutting edge and the work piece, it can cause issues during the hobbing process. Currently, Gleason uses a test fixture in which the load is manually applied to the arbor in one static direction and it is tedious, strenuous, and time consuming to run the test.

Our mission is to develop a new device to make their testing easier and more effective. Gleason Works has asked us to develop a way to apply a force up to 1000lbs (400lbs minimum) in the x, y, and z axes, so they can test the stiffness of their newly design hobbing machines in a timely fashion; meanwhile, making the device light enough to carry, easy to install, and small enough to be an accurate representation of the forces that occur during the hobbing process.

Gleason's Current Testing Apparatus

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Systems Design

In our systems design review, we brainstormed ideas to help develop a rough draft solution for the problem. Using morphological charts to identify various possibilities and combine ideas we developed a few different concepts. After comparing the various concepts using Pugh charts, we determined that our best option was the "Pivol Swivet," a device that clamped onto the arbor rod and was able to rotate by having 2 joints, one ball joint at the work piece and pivot joint connected near the arbor rod, with a hydraulic ram and loads cell connected linearly in between the two joints.

Subsystems Design

In the subsystem design phase we expanded upon our “Pivol Swivet” fixture. During that phase we performed various simulations and determined that the subsystems still needed to be modified in order to avoid interferences and withstand the load caused during operation. It was our first attempt at physically analyzing the capability, mechanical movements and strength of the Pivol Swivet.

Preliminary Detailed Design

More simulations were done to prove that the design would work, we started working on our drawing package, constructed preliminary test plans and a rough BOM.

Feedback

Based on our previous design review we were advised the following objectives:

Team Vision for Detailed Design Review

What We Planned to Do

What We Did

Team Schedule for MSD I (Gantt Chart)

Drawings, Schematics, Flow Charts, Simulations

Whole System Design Exploded View

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Customized Components Package

Custom Parts Package

Ball Joint Subsystem

Part No. 01 - Outer Socket

Drawing

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Outer Socket Drawing

Simulations

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Supplier/Source: Morgood (Outsourced Machined Component) - $270.00

Part No. 02 - Inner Socket

Drawing

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Inner Socket Drawing

Simulations

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Supplier/Source: Morgood (Outsourced Machined Component) - $290.00

Part No. 03 - Ball Rod

Drawing

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Ball Rod Drawing

Simulations

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Supplier/Source: Morgood (Outsourced Machined Component) - $150.00

Entire Pivot Sub Assembly

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Pivot Sub Assembly Drawing

Load Cell and Ram Subsystem

Part No. 04 - Load Cell

Drawing

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Supplier/Source and Model Number: Futek LTH350 FSH00361 - $560.00

Part No. 05 - Load Cell Block

Drawing

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Load Cell Block Drawing

Simulations

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Supplier/Source: In-House | Raw Materials from McMaster-Carr - $30.00

Part No. 06 - Retainer Plate

Drawing

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Retainer Plate Drawing

Supplier/Source: In-House | Raw Materials from McMaster-Carr - $8.00

Part No. 07 - #4-40 X 5/8' Socket Head Cap Screw

Supplier/Source and Model Number: McMaster-Carr 91251A112

Part No. 08 - Ram

Drawing

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Supplier/Source: Enerpac RSM-50 - $330.00

Part No. 09 - #8-32 X 3/8' Socket Head Cap Screw

Supplier/Source and Model Number: McMaster-Carr 91251A192

Entire Load Cell Sub Assembly

Load Cell and Ram Sub Assembly

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Slide Subsystem

Part No. 10 - Outer Slide

Drawing

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Outer Slide Drawing

Supplier/Source: In-House | Raw Materials from McMaster-Carr - $6.00 For Two Parts

Part No. 11 - Inner Slide

Drawing

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Inner Slide Drawing

Supplier/Source: In-House | Raw Materials from McMaster-Carr - $6.00 For Two Parts

Entire Slide Sub Assembly

Slide Sub Assembly

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Pivot Subsystem

Part No. 14 - Pivot Block

Drawing

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Pivot Block Drawing

Simulations

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Supplier/Source: In-House | Raw Materials from McMaster-Carr - $40.00

Part No. 15 - Rotary Encoder

Picture

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Drawing

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Supplier/Source and Model Number: US Digital MA3-A10-125-D - $70.00

Part No. 16 - Encoder Pin

Drawing

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Encoder Pin Drawing

Supplier/Source: In-House | Raw Materials from McMaster-Carr - $10.00

Entire Pivot Sub Assembly

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Clamp Subsystem

Clamp Machining Early Stages

Stage One Drawings

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Stage One Assembly.

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Stage Two Drawing

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Part No. 18 - Primary Clamp

Drawing

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Simulations

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Supplier/Source: Morgood (Outsourced Machined Component) - $330.00

Part No. 24 - Clamp Pin

Drawing

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Clamp Pin Drawing

Supplier/Source: In-House | Raw Materials from McMaster-Carr - $10.00 DOUBLE CHECK

Part No. 25 - Secondary Clamp

Drawing

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Simulations

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Supplier/Source: Morgood (Outsourced Machined Component) - $275.00

Part No. 22 - Clamp Bolt

Drawing

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Supplier/Source: McMaster-Carr - $10.00

Part No. 21 - Clamp Nut

Drawing

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Supplier/Source: McMaster-Carr - $4.00

Part No. 19 - Inclinometer

Picture

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Drawing

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Supplier/Source and Model Number: US Digital A2T-A-S-D - $350.00

Entire Clamp Sub Assembly

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External Load Application Components Subsystem

Part No. 32 - Pump

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Supplier/Source and Model Number: Enerpac P-392 - $0.00 (Product is being supplied by Gleason Works)

Part No. 31 - Pressure Release Valve

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Supplier/Source and Model Number: Brand Hydraulics RL50-2000 - $65.00 (Product is being purchased from Northern Tool and Equipment)

Electronics/GUI Subsystem

Part No. 27 - DAQ

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Pin Layout

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Supplier/Source and Model Number: Measurement Computing USB-201 - $100.00

Part No. 28 - Strain Gage Signal Conditional Amplifier

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Supplier/Source and Model Number: Futek FSH03863 - $425.00

Part No. 30 - Strain Gage Signal Conditioner Power Supply

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Supplier/Source and Model Number: US Digital PS-24 - $66.00

Part No. 29 - Inclinometer Power Supply

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Supplier/Source and Model Number: US Digital PS-12 - $20.00

Wiring Diagram

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GUI

GUI produced using Microsoft Visual Studio.

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Additional code required for program provided with DAQ.

Bill of Material (BOM)

BOM Chart

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Total Expenses: $3,470

Total Budget: $4,000

Percentage Used: 86.75%

Expense Breakdown

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Test Plans

The following tests will be performed in the manner described to establish proof that the device works as intended given the engineering requirements. This will include demonstrating the data collections components, user interface (GUI), and loading components perform as desired. In addition, showing that the device as a whole accomplishes it intended purpose, force application for stiffness testing.

The load cell used in conjunction will be tested off line of the test hobber initially to determine GUI accuracy in load measurement. The full device, with all data collection components and GUI, will be testing in the machine under typical testing example testing conditions.

The initial test will require that the load cell be placed into a device capable of applying its own load and measuring it. The device to be used for this test will be one of the several tensile/compression tester available in the COE. The GUI will be fully connected to the load cell as would be under typical operating conditions. The load cell will be placed in the tester so to load it in the typical operating fashion.

The primary test will require the completed device be installed in the test hobber in in the typical operating manner. The load cell, rotary encoder, and inclinometer will be fully linked to the GUI. The hydraulics will be fully connected as in typical operating conditions. Gleason will need to provide the measuring equipment they utilize in determining deflections.

The parameters to be measured in the initial test are as follows:

The parameters to be measured in the primary test are as follows:

The procedure for performing the initial test will require first establishing which testing machine will be used. Then it will need to be determined of the machine can provide compressive loading or if a simple rig will need to be constructed to adapt a tensile force into a compressive application to the sensor.

The required procedures for the machine will need to be followed but the process will be relatively simple.

1) Connect load cell (free) to the DAQ and the DAQ to the computer running the GUI, as per typical operating conditions.

2) Run the GUI, ensuring that the load cell is registering a zero load, note any variation.

3) Insert load cell into testing machine. Load cell x-section

4) Bring the testing machine software online.

5) Ensure that the machine is applying a zero load to the load cell.

6) Run the GUI, ensuring that the load cell is registering a zero load, note any variation.

7) Operate the testing machine, applying the loads detailed on DS1 as per typical operating conditions.

8) Note the LM and LG for the given loading condition.

9) Return testing machine to zero load.

10) Note any variation from zero for machine and GUI.

11) Repeat 7-10 5 times for each of the 4 loads with 3 different operators.

Test Plan 1 Data Sheet

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The process for the primary test will require information from Gleason as to the loading conditions they have previously tested on the test hobber. This will include the results of the deflections.

1) Allow each of the three testers to perform the following as per typical operating conditions to gain experience and understanding of the setup.

a) Mount the device to the test hobber as per typical operating conditions.

b) Connect the hydraulics to the device.

c) Connect the device to the DAQ and the DAQ to the computer running the GUI.

d) Run GUI

2) Repeat above, collecting TI.

3) Repeat this 2 times with 3 different operators.

4) Position the device into the “zero” position, the device orientated only in the machine x direction.

5) Using a digital level, positon, as per typical operation, the pivot, then the arbor clamp, into the specified conditions as per DS2-1.

6) Note the angle measured by the digital level and the GUI.

7) Repeat 4-6 5 times with 3 different operators for each condition.

8) Position the device into the “zero” position, the device orientated only in the machine x direction.

9) As per the listed conditions in DS2-2, enter the loading condition into the GUI.

10) Position the device as per typical operation into the orientation indicated by the GUI.

11) Apply hydraulic pressure until the desired load is reached, as indicated by the GUI.

12) Note the total, L, and component (LX, LY, LZ) loads given by the GUI.

13) Repeat 5 times with 3 different operators for all 4 conditions.

14) Given previously tested loading conditions by Gleason, follow steps 8-11, replacing the DS2-2 conditions with the Gleason conditions.

15) Measure the time to accomplish 14 (TL) and the same deflections measured by Gleason (DP).

Test Plan 2 Data Sheets

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Device Validation Test Plan

Data Sheets

Engineering Requirements Relation

Risk Assessment

FMEA

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Detailed Design Review FMEA Document

Risk Assessment Chart

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Detailed Design Review Risk Assessment Document

MSD II Schedule

MSD II Phase 1 - Build and Test Prep

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MSD II Phases 2-5

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Team Schedule for MSD II (Gantt Chart)

MSD I Lessons Learned

Feedback to MSD Program


Post Detailed Design Review Items

After presenting our final design review, we were given some suggestions on how to improve our drawing package, electrical devices layout, BOM and MSD II schedule. The final versions of each item are listed below.

Drawing Package

Final MSD I Drawing Package

Electrical Devices Layout

After the review we have determined to create a platform for the electrical devices that are external to the Pivol Swivet. To do this we are going to contain the devices inside of watertight plastic enclosure seen below here:

Enclosure

We were also asked to show wiring and strain relief devices. The links for which are below:

Inclinometer Wiring

Encoder Wiring

Strain Relief

Bill of Materials

Final MSD I BOM

Final MSD II Schedule

Final Team Schedule for MSD II

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