Team FOAM Design Team 6 Members: F redrik Sy, D ainis Nams, A llison Chua, M otaz Taha Advisor: Dr. Darrel Doman Client: Precise Designs Engineering Solutions 1

Contents  Background  Requirements  Final Design  Testing  Final Product  Requirements Check  Conclusions  Future Work  Acknowledgments 2

Background  Client’s production requires foam profile cutting  Current method is water jet cutting:  Outsourced  Long drying time  Client wants to cut foam using in house machine shop Polyplank foam ( 3

Requirements 4 Essential RequirementsImportant Requirements SafetyBudget : $3000 Interface with CNC machineEase of installation and detachment Arbitrary pocket profilesAcceptable cut speed 1/4 in. minimum hole dimensionCut tolerance of 1/32 in. Cut depth of 4.75 in.Body overall length less than 6 in. Acceptable cut quality Minimal need for cleaning or replacing parts

Design Overview  Design divided into subsystems:  Cutting element  Cutting element holder  Rotational power transfer  Body and CAT40 mounting  Temperature control Five Subsystems 5 Body And CAT40 Mounting Rotational Power Transfer Cutting Element Cutting Element Holder Temperature Control

Final Design 6 Collet Holder Bracket Attachment And Plugin Slip Ring Cutting Element CAT40 Head CNC Head Bracket Slip Ring Attachment Power Jack Conical Pin

Final Design 7 CNC Head Bracket Slip Ring Cutting Element CAT40 Head Wiring Terminal Power Plugin And Slip Ring Bracket Attachment

Temperature Control 8  Custom fabricated on-off control  Uses thermocouple signal to modulate power to resistive element  Toggles around set temperature (±10°C)  Adjustable set temperature Temperature Control

Testing Goals 9  Determine a measure for quantifying cut quality  Cut quality was measured as a function of:  Feed speed  Temperature  Determine minimum wall thickness of cut foam  Determine ability to interface with CNC machine  Determine cut tolerances and minimum hole dimension

10  Qualitative scale to measure quality of cuts Quality Index (1) (2) (3) (4)

Performance Testing 11  Single Axis Foam Feeder  Temperature tests  Feed speed tests  Long deep cut tests

Performance Results: CNC Interface 12  CNC interface  Automatic tool changer

Performance Results: CNC Foam Cutting 13  Cut direction determines quality  One side has good quality  Milling: spiral outwards  50% overlap, 1/8 in. increments  Minimum wall thickness of 0.5 in.  Variable depth pockets Tool PathCutting Increment Remaining Foam Pocket

CNC Foam Cutting 14  Pocket created for 3 way solenoid valve  Pocket has 3 depth levels

CNC Foam Cutting Video 15

CNC Foam Cutting: Example Product 16

Operational Parameters 17

Requirements Check 18 Essential RequirementsImportant Requirements SafetyBudget : $3000 Interface with CNC machineEase of installation and detachment Arbitrary pocket profilesAcceptable cut speed 1/4 in. minimum hole dimensionCut tolerance of 1/32 in. Cut depth of 4.75 in.Body overall length less than 6 in. Acceptable cut qualityAutomatic tool changer interface Minimal need for cleaning or replacing parts Variable depth pockets

Cut Tolerance 19  Mostly acceptable cut tolerance (1/32 in. )

Conclusions 20  Alternative method to water jet cutting developed  Final design constructed  Final design tested  Operational parameters of foam cutting tool determined  Project requirements exceeded  Automatic tool changer  Variable depth pockets

Future Refinements 21  Purchase slip ring with higher RPM  Construct a variety of cutter sizes and shapes

Acknowledgements  Project Supervisor: Dr. Darrel Doman  Design Project Course Coordinators: Dr. Andrew Warkentin And Dr. Julio Militzer  Client: Precise Designs Engineering Solutions  Shell  ROV Team  Dalhousie Staff  Angus MacPherson  Jon MacDonald  Albert Murphy  Mark MacDonald  Ray Newman  Rob Warner  SolidWorks 22

Safety Regulations (1)  Purpose:  The purpose of this document is to outline the safety procedures to be followed for any testing to be done in the TEAM FOAM project and specifies the responsibilities of the individuals performing said testing or experiment. The document also outlines requirements in the procedures of these experiments and testing.  General Safety Procedure:  This section applies to all testing. Any testing done with heating elements, electrical devices or any device that may bring bodily harm requires the presence of at least two people performing the experiment. Each person is responsible for both himself/herself and for every other person performing the testing to abide by the safety procedure outlined in this document.  Should one person be injured or incapacitated, it is the responsibility of the all the members performing the test to ensure that immediate and proper treatment be applied 23

Safety Regulations (2)  Heating elements:  This section pertains to all testing done with any heating elements. The following safety equipment/procedures must be used:  Safety Glasses  Gloves with thermal insulation sufficient for the temperatures of the experiment  No open toe footwear  The heating element must be at least 5 feet away from any easily combustible fuel  The heating element must not rest or be held in place with chance of heating element igniting any object. 24

Safety Regulations (3)  Electrical power supplies:  This section pertains to constructing electrical circuitry or mechanism that convey/interact in some way that are not inherently electrically insulated. The following safety equipment/procedures must be used:  Safety Glasses  Gloves with electrical insulation  The electrical equipment must be at least 5 feet away from any easily combustible fuel so as to avoid the chance that a spark ignites the fuel.  The testing mechanism must be designed such that the mechanism cannot draw power unless the person using the mechanism is not at least 3 feet away from the equipment. 25

Budget 26 INCOME VALUE Requested support from Dalhousie University, Mechanical Engineering $ Requested support from Precise Designs $ 3, Total income $ 3, EXPENSESQUANTITYUNIT PRICETOTAL PRICESUPPLIER Prototype supplies 1/16 in. diameter spring steel rod1 $ 3.00 Maritime Hobbies & Crafts Knife1 $ 3.00 Buck and Near Dollar Store Motor1 $ 10.00Princess Auto Muffler tape1 $ 6.00 Canadian Tire Oven element2 $ - Team member Switch1 $ 3.00 Princess Auto Final design supplies Subsystem 1: Cutting element 1/4 in. stainless steel tube6 X 12" $ Hobbylinc.com 20 gauge Nichrome 80 resistance wire with double glass insulation1 X 50' $ Pelican Wire Co., Inc. 6 in. 2-Way cross-slide vice, product # $ Princess Auto Subsystem 2: Cutting element holder ER-20 collet chuck, 3/16 in.1 $ Royal Product ER-20 collet chuck, 1/4 in.1 $ Royal Product ER-20 collet chuck, 1/2 in.1 $ Royal Product Subsystem 3: Rotational power transfer Slipring, model AC $ Moog Components Group Variac, model 6994K241 $ McMaster-Carr Subsystem 4: Body and CAT40 mounting ER-20 CAT40 collet chuck holder1 $ Royal Product Other (i.e. wiring, hardware, bearings)- $ Various Technician time from Dalhousie UniversityN/A $ - Dalhousie University Technican time from Precise DesignsN/A $ - Precise Design Paperwork costs (i.e. printing, faxing)N/A $ Various Shipping (estimated)N/A $ Various Tax (15%)N/A $ $ N/A Contingency fund (20%)N/A $ $ N/A Total expenses $ 2,162.56N/A EQUITY BALANCE $ 1,037.44

Construction Of Cutting Element 27 Connection Wires To Slip Ring Thermocouple Wires Resistance Wires Steel Tube

Detailed Design Parameters 28  Budget : Spent $  Under budget by ~ $1 300  Overall length ( to beginning of element) is 4.25 in.