1. 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

2. Contents  Background  Requirements  Initial Testing  Design Alternatives  Final Design Selection  Prototype  Future Work 2

3. 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 (www.casecad.com) 3

4. Essential Requirements  Safety  Interface with CNC machine head  Arbitrary pocket profiles  Minimum hole dimension of 1/4 in.  Cut depth of 4.75 in.  Acceptable cut quality  Minimal need for replacing or cleaning parts 4

5. Important Requirements  $3,000 budget  Ease of installation and detachment from CNC machine  Acceptable cut speed  Cut tolerance of 1/32 in.  Body not longer than 6 in. 5

6. Current Methods Water Jet Cutting (http://www.aqua-dynamics.co.uk) 4 Axis CNC Wire Foam Cutter (www.hotwiredirect.com) Die Cutter (www.chiyodaintegreusa.com) 6

7. Project Idea  Heated bit cutter  Fluted bit versus round bit  Temperature range to produce acceptable cut quality  Rotation versus no rotation  Knife cutter  1/4 in. holes  Corners 7

8. Heated Rod Testing  Experimental setup:  Fluted and round bits  Standard drill press  Oven: controlled temperature Measuring Oven Temperature Thermally Insulating The Bit Performing Foam Cuts With Round Bit 8

9.  Results:  Round bits perform better cut quality  Temperature range required: 180-200˚C  Rotation is required Uneven Cut Quality Poor Cut QualityGood Cut Quality Heated Rod Testing Results 9

10. Knife Cutter Testing  Constructed a prototype of thin blade cutter  Results:  Excellent cut quality  Difficult to follow tight corners Knife Prototype 10

11. Design Alternatives  Design divided into subsystems:  Cutting element  Cutting element holder  Rotational power transfer  Body and CAT40 mounting Four Subsystems Body And CAT40 Mounting Rotational Power Transfer Cutting Element Cutting Element Holder 11

12. Cutting Element  Two main alternatives generated: 2. Thick Cutting Element 1. Thin Cutting Element 12

13. Cutting Element Holder  Three main alternatives generated: 1. Standard, Off-The-Shelf Chuck 2. Standard, Off-The-Shelf Collet 3. Insulated Set Screw Holder 13

14. Rotational Power Supply Attachment  Rotational power supply through slip ring  Two main alternatives for attachment of slip ring: 1. Magnetic Attachment 2. Bracket Attachment 14

15. Body And CAT40 Mounting  Two main alternatives generated: 1. Integrated CAT40 Collet Holder 2.Generic CAT40 With Custom Body 15

16. Final Design Collet Holder Bracket Attachment Slip Ring CNC Machine Head Thick Cutting Element 16 Final Design CAT40 Head

17. Design Project Status  Slip ring prototype  >10 Amps  Thick cutting element prototype  Can cut foam Slip Ring Wires PVC Tube Cutting Element Contact With Resistance Wire 17 Slip ring prototype

18. Cut Quality  Comparable cut quality Water Jet Cut FoamTeam FOAM Cut Foam 18 Cut Surface

19. Future Work  Further Prototyping  Cutting Element  Temperature Regulation  Ordering Components  Final Design Construction 19

20. Acknowledgements  Project Supervisor: Dr. Darrel Doman  Design Project Course Coordinator: Dr. Andrew Warkentin  Dalhousie Technician: Angus MacPherson  Shell  SolidWorks  ROV Team  Client: Precise Designs Engineering Solutions 20

21. 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 21

22. 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. 22

23. 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. 23

24. Thermal Imaging Results  Very poor temperature gradient in thin element heated at top Heating Source Thin Rod Heated Thin Blade 24

25. Thermal Imaging results (2)  Uniform Heat Distribution (resistance wire in core) Uniform Heat Distribution Chuck Cool Top 25 Heated Oven Element

26. Knife Cutter Testing Freely Spinning Joint Thin Knife Blade 26

27. Knife Cutter Testing  Corner Cuts: 27 Cut Surface

28. Budget 28 INCOME VALUE Requested support from Dalhousie University, Mechanical Engineering $ 200.00 Requested support from Precise Designs $ 3,000.00 Total income $ 3,200.00 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" $ 16.50 Hobbylinc.com 20 gauge Nichrome 80 resistance wire with double glass insulation1 X 50' $ 34.00 Pelican Wire Co., Inc. 6 in. 2-Way cross-slide vice, product #81281591 $ 99.00 Princess Auto Subsystem 2: Cutting element holder ER-20 collet chuck, 3/16 in.1 $ 20.00 Royal Product ER-20 collet chuck, 1/4 in.1 $ 20.00 Royal Product ER-20 collet chuck, 1/2 in.1 $ 20.00 Royal Product Subsystem 3: Rotational power transfer Slipring, model AC4598-61 $ 384.48 Moog Components Group Variac, model 6994K241 $ 368.09 McMaster-Carr Subsystem 4: Body and CAT40 mounting ER-20 CAT40 collet chuck holder1 $ 180.00 Royal Product Other (i.e. wiring, hardware, bearings)- $ 300.00 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 $ 50.00 Various Shipping (estimated)N/A $ 50.00 Various Tax (15%)N/A $ 233.56 $ 235.06N/A Contingency fund (20%)N/A $ 358.13 $ 360.43N/A Total expenses $ 2,162.56N/A EQUITY BALANCE $ 1,037.44