P19603: Rod Feeding Mechanism
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Problem Definition

Table of Contents

Phase Review Agenda

Team Vision for Problem Definition Phase

What we wanted to achieve

What we achieved

Not yet Achieved

Project Summary

Metal additive manufacturing machines primarily use either wire or powder feedstock. Powdered metal is expensive and wire is hard to source for alloys that are not used in welding. The use of bar stock would be ideal, as most metals are readily available in rod form, but no standard exists for using rodstock in metal AM applications.

The goal of this project is to develop a standard for a feed mechanism which will enable the use of various bar stock materials in metal AM applications, particularly the Vader AM machine in RIT’s Brinkman lab. The design must provide stock material fast enough to avoid slowing the machine down, without overfilling the microcrucible or negatively impacting part quality. The device must also be safe for both operator and machine, and be simple to use. While integration with the Vader is ideal, it is not the primary goal of this project.

1 page project summary here.

Motivation

Primary benefits: Cost savings and use of different materials.
Material Cost Comparison

Material Cost Comparison

Project Goals and Key Deliverables

Stakeholders

Stakeholder Position
Dr. Cormeir Project Sponsor
Gary Werth Project Guide
MSD Team Product Developers
Dinesh and Khushbu Machine Operators
Chris Fisher Purchasing Director

Stakeholder Interviews

Notes from Customer and User interviews can be found here: All Interviews
Date Person Interviewed Document
August 30, 2018 Dr. Cormier Customer Interview 1
August 31, 2018 Dinesh and Khushbu Operators Interview 1
September 10, 2018 Dr. Cormier Customer Interview 2
September 13, 2018 Dr. Cormier Phase 1 Review

Use Cases

Use Case 1

Use Case 1

Use Case 2

Use Case 2

Use Case 3

Use Case 3

A working document can be found here: Use Cases Charts

Customer Requirements (Needs)

Customer Requirements

Customer Requirements

Below are more detailed descriptions of our customer requirements:

The live document is here.

Constraints

Primary Constraints

Engineering Requirements (Metrics & Specifications)

Engineering Requirements

Engineering Requirements

Below are more detailed descriptions of our engineering requirements and constraints:

A spreadsheet was created to calculate the feedrate needed for a rod. Using the average drop size, the average print rate of the Vader machine, and the size of the rod, its feedrate was determined. The spreadsheet below summarizes these calculations:

Feed Rate Estimation

Feed Rate Estimation

The live document is here.

House of Quality

The House of Quality compares the relationship between the Customer Requirements, the Engineering Requirements, and the Constants.
House of Quality

House of Quality

Link to the live document here.

Plans for next phase

Owner Task 1 Task 2 Task 3
Mark Look into comparable products to go into prototyping/ideation phase Keep open communication with AMprint center and stakeholders
Josh Research/benchmark relevant existing machines Brainstorm and generate design concepts Assemble a Pugh chart for concept selection
Connor Research basic concepts of the MSP430 microcontroller Researching type of sensors and actuators we can use
Ryan Learn purchasing stystem Start prototyping storage and loading mech concepts
Mathias Read Vader User Manual and understand operation Select Microcontroller for use in design Talk with Dinesh and Khushbu about Vader operation
James Create project plan for phases 3 and 4 Research rod handling in industry Draft functional decomposition

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