Project SummaryThe hobbing process is a method of generating gears where both workpiece and machine tool rotate simultaneously. When creating gears in a manufacturing process, the importance of maintaining product quality and meeting the required tolerances of said gear allows the manufacturer to be competitive in the machining market. A great influence on final product quality can be caused by the stiffness of the hobbing machine frame(s). As such, a system that is capable of applying the forces experienced during the hobbing process to the machine (static and dynamic) in a controlled and repeatable manner is desired. Currently, the Gleason hobbing machine's stiffness is measured through the use of a rudimentary test fixture.
The goals of the project are to analyze the current design and to create a more robust device capable of producing multi-axial static loads comparable to process loads. The following project will seek to improve device functionality through improved ease of use, repeatability of the process, and accuracy in applying a static load in three dimensions. The resulting design and prototype should be able to provide the desired forces in the desired directions as well as to the desired components. It should be able to do this in a controlled and repeatable manner. The prototype should be able to withstand normal manufacturing environments as it should mount within the confines of the machine while it is in an operating mode. Weight and complexity of the system should be designed to appropriate human engineering standards and to allow ease of use.
Project Goals and Key Deliverables
- Design and create a device to attach to a Gleason hobber, apply multi axial loads of desired magnitudes so that deflections can be measured repeatably.
- The device must be adaptable to any Gleason hobbing machine but will be tested and demonstrated on the Gleason Hobber 400 Series (located in the RIT KGCOE machine shop).
- Applicator: A device containing a series of actuators that are capable of applying the desired forces, arranged so to apply them in the desired directions. Should be completely contained within the available area within the hobber, sans energy supply.
- Sensors: One or a series of sensors with which to measure accurately the magnitude of force being applied to the hobber in the various directions.
- Controls: Develop a method of controlling the application of force so that it is repeatable and allows direct operator use. Also control the input of energy into the system.
Customer Requirements (Needs)
Engineering Requirements (Metrics & Specifications)
House of Quality
- Fits within Gleason 400 hobbing machine
- Costs less than $4000
- Completed within time of MSD (Imagine RIT)
- Within the abilities of a team of mechanical engineers (primary)
Summary of Problem Definition Design ReviewWhat did we do in this phase?
- Defined the scope for this project (problem statement).
- Identified the key goals and deliverables of the project.
- Developed an understanding the hobbing process, and establish communication with Gleason Works and Mike Walker.
- Discussed possible uses for the device we will be designing and creating.
- Identified customer requirements and create engineering requirements based on them.
- Began benchmarking and identifying similar products.
- Identified possible risks moving forward.
- Established a common communication medium using GroupMe appliation.
- Established a task manager medium using Trello application.
- Documented norms and values to which we can actively receive peer reviews from our team members. Team Values and Norms
- Drafted a project plan for the next phase (see below).
Phase 2 - Systems Design
Goals for Phase 2
- Visit Gleason Works (Tuesday 9/15/15)
- Develop a functional decomposition.
- Finalize benchmarking.
- Demonstrate Feasibility of technology.
- Generate a design concept.
- Divide the design into sub-functions for a narrower view to see finer details of the project.
- Review risk assessment and update appropriately
Phase 2 - Systems Design Preliminary Gantt Chart
- Contact Dr. Liu and understand his role in the project.
- Constantly update risk assessment.
Phase 3 and Beyond Preliminary Gantt Chart
Click here for Microsoft Project Gantt Chart File
Click here for Gantt Project Gantt Chart File
Click here for PDF of Gantt Chart File
Be advised that Gantt chart was created using the GanttProject Software; therefore, there is likely to have less problems while using that program (as opposed to Microsoft Project).
Design Review Notes
Notes from review
- Do you have task ownership and a way to track owner completion? Yes, Trello
- All ER’s are “Test to Validate” Be careful about 80% repeatability
- Constraints are “Meet or Not”
- Use Scenarios 1-3 are identical, only other one should be “Use At Customer site”
- Is time required to test machine an ER or a constraint?
- Don’t confuse OSHA with safety requirements
- Communicate communication plan to Gary
- Update ER's and constraints to reflect changes.
- Improve communication methods.