P16665: Gleason Hobbing Machine Force Applicator

Preliminary Detailed Design

Table of Contents

Background Information

Quick Project Overview

Gleason currently uses a test fixture in which the load is manually applied to the arbor in one static direction. In the subsystem design phase we expanded upon our “Pivel Swivot” fixture, which was approved from the system design review. 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. During the preliminary detailed design phase we finalized our subsystems so that they can withstand forces with a factor of safety of 2.0-2.5, while not interfering with any other components during operation. We have also put a larger focus on mitigating risks, so that we do not run into issues when we are building the device in MSD II.

Team Vision for Preliminary Detailed Design Phase

What We Planned to Do

What We Did

Drawings, Schematics, Flow Charts, Simulations

Whole System Design

public/Detailed Design Documents/GUI/PDD/Line Routing.png

public/Detailed Design Documents/Drawings/System.JPG

Whole System Design Exploded View

public/Detailed Design Documents/Drawings/Exploded.JPG

Finalized Ram and Pump

public/Detailed Design Documents/Ram/Ram_Drawing_inches.JPG

Enerpac RSM-50. Dimensions in inches.

Discussion with Mike indicated that a system for supplying the hydraulic pressure, similar to the one pictured below, will be available for testing.

public/Detailed Design Documents/Ram/Hydraulics.JPG

Overload protection will be provided by an adjustable relief valve, set to a desired pressure given the application.

public/Detailed Design Documents/Ram/Pressure_relief.JPG

public/Detailed Design Documents/Ram/Pressure_relief_specs.JPG


public/Detailed Design Documents/Drawings/Clamp_Primary.JPG

public/Detailed Design Documents/Drawings/Clamp_Secondary.JPG

public/Preliminary Documents/Clamp pin.PNG


public/Preliminary Documents/pivot_block.PNG

public/Preliminary Documents/Encoder Pin.PNG

Slide Design

public/Preliminary Documents/Outer_Slide_drawing_pjh.PNG

public/Preliminary Documents/Inner_Slide_drawing_pjh.PNG

Load Cell Housing

public/Preliminary Documents/Load cell block.PNG

Finalized Load Cell

public/Detailed Design Documents/LoadCell/LoadCellDrawing.jpg

Ball Joint/Work Piece Components

public/Preliminary Documents/Ball_rod_drawing_vf.PNG

public/Preliminary Documents/Outer Socket.PNG

public/Preliminary Documents/Inner Socket.PNG

public/Preliminary Documents/Retainer Plate.PNG


GUI produced using Microsoft Visual Studio.

public/Detailed Design Documents/GUI/PDD/C_Front.PNG

Additional code required for program provided with DAQ.

Tolerance Stack

public/Preliminary Documents/ToleranceStack.png


Interferences with Moving Part Simulation

public/Preliminary Documents/Ginference.gif

Applied Load Simulations


public/Detailed Design Documents/Simulations/MSD Simulations Nov/Clamp_primary_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Clamp_primary_results.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Clamp_secondary_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Clamp_secondary_results.JPG


public/Detailed Design Documents/Simulations/MSD Simulations Nov/Pivot_Block_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Pivot_Block_results.JPG

Load Cell Block

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Load_cell_block_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Load_cell_block_results.JPG

Ball Joint

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Ball_Joint_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Ball_Joint_results.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Inner_socket_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Inner_socket_results.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Outer_socket_setup.JPG

public/Detailed Design Documents/Simulations/MSD Simulations Nov/Outer_socket_results.JPG

Whole System Simulations

The following illustrate the device loaded in only the X/Z direction. Displacement constrains are of zero displacement in X,Y,Z:

public/Detailed Design Documents/ANSYS/XLoad.jpg

public/Detailed Design Documents/ANSYS/XLoad_Stess.jpg

public/Detailed Design Documents/ANSYS/XLoad_Def.jpg

public/Detailed Design Documents/ANSYS/XLoad_Safe.jpg

The following illustrate the device loaded in only the Y direction. Displacement constrains are of zero displacement in X,Y,Z:

public/Detailed Design Documents/ANSYS/YLoad.jpg

public/Detailed Design Documents/ANSYS/YLoad_Stess.jpg

public/Detailed Design Documents/ANSYS/YLoad_Def.jpg

public/Detailed Design Documents/ANSYS/YLoad_Safe.jpg

The following illustrate the device loaded equally in only the X,Y, and Z directions. Displacement constrains are of zero displacement in X,Y,Z:

public/Detailed Design Documents/ANSYS/XYZLoad.jpg

public/Detailed Design Documents/ANSYS/XYZLoad_Stress.jpg

public/Detailed Design Documents/ANSYS/XYZLoad_Def.jpg

public/Detailed Design Documents/ANSYS/XYZLoad_Safe.jpg

GUI Test Bench Simulations

As the DAQ has not yet been able to be purchased, the testing of the GUI has been limited to verifying the math using LabView.

public/Detailed Design Documents/GUI/PDD/GUI_Code.PNG

The current axis of the device is abitrary and will need to be determined based on final sensor positioning and load definitions.


Quotes Received

RIGHT CLAMP 1018 MATL $330.00

LEFT CLAMP 1018 MATL $275.00

INNER SOCKET 1018 MATL $240.00

OUTER SOCKET 1018 MATL $240.00

PIVOT PIN 1018 MATL $75.00

TOOLING BALL 4140 PH $100.00

Bill of Materials (BoM)

public/Preliminary Documents/IndenturedBOM.jpg

List of Purchase Orders Completed

Low Profile Hydraulic Cylinder- $319.00

Donut Load Cell 2000LB Capacity- $560.00

Hydraulic Cylinder PO

LoadCell PO

Test Plans

Test Plans

Preliminary Usage/Safety Manuals

Users Manual

Two "User Manuals" will be provided, a generic one and one specific to the test hobber.

They will include five sections as follows:

1) Safety First.

2) The Device:

3) The Ram:

4) The GUI:

5) A Test:

Safety Documents

Areas of Concern:

public/Detailed Design Documents/Risk Assessment/SafetyPrecautionsDocumentSnip.JPG

Applying a sticker to the device such as the one below is another option.

public/Detailed Design Documents/Risk Assessment/PinchPoint_Warning.JPG

Image provided by mysafetylabels.com

Safety Precautions Document

Risk Assessment


public/Detailed Design Documents/Risk Assessment/FMEA_PDDR_CRITICAL.JPG

public/Detailed Design Documents/Risk Assessment/FMEA_PDDR_MAJOR.JPG

public/Detailed Design Documents/Risk Assessment/FMEA_PDDR_ORDINARY.JPG

Preliminary Detailed Design Review FMEA Document

Risk Assessment Chart

public/Detailed Design Documents/Risk Assessment/TechnicalRisksSnip_PDDR.JPG

public/Detailed Design Documents/Risk Assessment/ResourceRisksSnip_PDDR.JPG

public/Detailed Design Documents/Risk Assessment/SafetyRisksSnip_PDDR.JPG

public/Detailed Design Documents/Risk Assessment/EnvironmentalRisksSnip_PDDR.JPG

Preliminary Detailed Design Review Risk Assessment Document

Areas we are still worried about

Plans for next phase

Team Schedule (Gantt Chart)

Lessons Learned

Home | Planning & Execution | Imagine RIT

Problem Definition | Systems Design | Subsystem Design | Preliminary Detailed Design | Detailed Design

Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Integrated System Build & Test with Customer Demo | Customer Handoff & Final Project Documentation