Build & Test Prep
Table of Contents
Team Vision for Build & Test Prep PhasePhase Objectives:
In this phase the team would like to accomplish these tasks:
- Create Semester Vision
- Design Plan for Mold Creation and Testing
- Purchase Materials
- Review Budget
- Contact labs on Campus for use of Equipment
- Create Test Plans
- Reach out for Business Students
- Look Deeper in Costs
- Provide Final Mold Design
In this phase, the team has divided these goals into these themes and assignments:
- Matt - will be leading test plans, as well as training for testing samples
- Derick - will be leading project planning tasks, budget and process integration
- Dan - will be in in charge of the mold creation, and well as material design and research
- Connor - will be in charge of researching risks and manufacturing costs
MSD I Re-Cap and Winter Break Updates
Re-Cap of Detailed Design
For those that were unable to attend the presentation for the the Detailed Design Review, click HERE for a link to our EDGE page. Some of the major decisions and accomplishments from this phase and review were:
- Creation of all the Sample Tiles
- Incorporation of Top Tile Design to full roof
- Discovery of ECO SUR SOUTH
- Reaching out to possible sponsors for Materials
Since our last review, the team has been focusing on:
As of this Phase, the team has spent about 44% of the allowed budget on the project. Below is a table showing budget allocation for the project:
Design of Experiments
With the Samples created and cured, the next step of the DOE is to test each sample. This includes reaching out to Lab Coordinators to find time for training and time to test. Matt was able to train with the Lab Coordinator. Below is a picture of our fully cured samples:
After finding out that the process was already established in other regions on Nicaragua, the team was been using ECO SUR South's process to benchmark against, to be able to create a tile and process that would be able out compete and out live current Mirco-Concrete Companies in the market. Below is a link to an informative video about the process used by ECO SUR SOUTH.
Creation of Tile via Eco-Sur South Equipment and Method - https://www.youtube.com/watch?v=tyAwpJ8D_mk
Putting Tiles on the Room Framing - https://www.youtube.com/watch?v=N2hyZ7_mhW0
Dan has been leading the Mold Design for the team. More on this topic below in other sections.
The manufacturing flowchart has not changed since the last phase. Some of the steps did have some sub-process changes, which added new materials to the manufacturing BOM. Here is the Flowchart for a Review:
To show what was worked on, and what is being worked on, and what needs work, below is a systems architecture. The purple is what was planned to be started in MSD II, and the red is what was finished in MSD I.
Addition of Business TeamLeslie Moore was able to share this project with one of his project based classes, and the addition of students from the Saunders School of Business will be joining the project this semester. The week of Feb 5th will be when preliminary discussions will occur about deliverables, skills and expectations.
Test Plan Summary
Concrete Strength TestArrangements have been made to begin sample testing on February 6th, 2018 with completion expected by February 9th, 2018. These results will test us the strongest mixture. From there, we will determine the most feasible combination of materials to use to make out tiles.
The samples will be test based on ASTM C293 Concrete Center Point Loading.
Mold Materials TestIn order to prepare for using the vacuum former, it was decided that we would conduct a test on two different types of styrofoam with two different protective coverings to determine which performs best. Our initial test plan involved more material types, but the cost of such a test was too high and we reduced it to only the necessities. We will have two samples each of styrofoam and smoothfoam, and cover these samples with bondo and plaster of paris. We will vacuum form over these samples with a piece of 1/8 inch thick ABS, and make the positive for the mold out of whichever material performs best.
Tile TestsTo recap, below is are plans we have to test each engineering requirement.
Below are the test instructions and documents:
- Solar Heat Gain
- Water Durability
- Wind Resistance
- Waterproof Test
New Mold DesignBefore this phase, we were deciding between one of two mold designs, which we called "stackable mold" and "nub mold".
Through our research of other examples of tile making, we discovered that the method used by Eco-Sur and by the previous tile team to achieve the best of both worlds for this problem was to pour the concrete into a frame that contained molds for the nubs, as shown below:
when the frame is lifted, the two nubs remain, due to the concrete's tendency to retain its shape (like wet sand). This flat tile is then slid onto the mold, and these molds are stacked onto each other with enough offset to allow for the height of the nubs. This design allows for stackable molds, the use of only one mold per tile instead of two, and keeps the nub from having to be attached separately. The mold was redesigned according to this.
The upside-down nature of the mold also negates the risk of any concrete slipping off the sides of the mold while drying. Now that the plastic is not being supported from underneath, it was necessary to analyze the amount of bending that would occur in the mold once fully weighted with concrete. To do this, the mold was modeled in Creo with constraints put around the edges of the mold and an 18 lb load distributed evenly across the surface.
The results of this simulation show that a 1/8th inch thick plastic mold would be able to support the weight of a tile with very little deformation.
Above is the Bill of Materials for one mold of the new design, not including the form that will be vacuum formed over.
Manufacturing PlansDesign possible layout(s) of the facility including where each process step would be completed, explaining how the layout allows for smooth flow of people, materials and information.
Evaluate the cost of the manufacturing setup including the cost of machines, materials, consumables.
Addition of two business students to the project will allow for help with supply chain management.
Risk and Problem TrackingBelow is a Risk assessment table showing the updated Risks for this Phase:
Plans for next phasePlanned Action Items in this Phase that we didn't finish:
- Sample 3 Point Testing: Material Science Lab use requires training, as well as specific timings.
- Mold Materials Testing: Collaboration fell through, with other teams being slow to respond, or denying requests.
The team will focus on these deliverables in the next Phase:
- Testing of Materials for Mold Creation
- Creating Mold
- Finalizing DOE results
- Have Larger focus on Manufacturing
- Begin Purchasing Materials for Test Roof
- Integrate Business Students into Team
Below is a Gantt chart for our plan.
Our Vision of the Imagine RIT exhibit:
- Completed Test Roof
- Poster with Information of Testing in El Sauce
- Completed Tests