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Senior Design Team 05: Gleason Works – Chamfering and Deburring Project Critical Design Review
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Team Introduction Project Manager:Vincenzo Mansueto-ME Lead Engineer:Matthew Liddick-ME Team Member:Brian Banazwski-ME Team Member:Mark Trotta-ME Team Member:Julie Wilcox-ME Team Member:Phil Raduns-EE Team Member:Greg Baesl-ISE Faculty Advisor: Bill Scarbrough Gleasons Representative: Eric Mundt
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Company Background Leading world-wide supplier of gear cutting technology Subdivision of Gleason Corporation Primary Market Automobile and truck industries Secondary Market Aerospace, Farm, Construction, Marine
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Defining the Need Cutting process for creating gears leaves behind sharp edges and burrs Danger to workers Gear strength Contamination Aesthetic Two current processes need improvement or modification
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On Machine Apparatus Not capable of tilt in both directions Has no scrapper Burrs still exist after chamfer
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GTR 250 Too slow 30 rpm max on work spindle Too expensive Accuracy of machine is excessive for process Large footprint
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Design Requirements and Deliverables Requirements Chamfer and deburr in same cycle Capable of machining various sizes of gear sets Price below $130k Cycle time under 1 minute As many commercial parts as possible Decrease footprint Deliverables Top level ProE drawings Market assessment
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Design Proposal ~70% smaller foot- print than GTR More tilt capabilities than both existing Lower cost
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Process Demonstration
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How we arrived at our design Work Break-down Structure Cutting Tool Apparatus Work Piece Apparatus Stock Divider Electronics Enclosure Customer Interactions Current process investigations
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Tilt Structure
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Stock Divider
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Time Study
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Max Torque Curve
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Electrical Components Servo/Spindle Motors Drives CNC Controller
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Cost Analysis Phoenix Stand AlonePhoenix with Chamfering unitNew Chamfering Machine Cost of Machine $675,000$680,000$130,000 Hours Operated 20800 Cost per Hour $32.45$32.69$6.25 Man Power per Hour $40.00 $0.00 Total Cost per Hour $72.45$72.69$6.25 Cycle Time SecondsHoursCycles per HourCycles per YearCost per Year Phoenix with Chamfering 1130.0313931.86132531$302,400.00 Phoenix without Chamfering 930.0258338.71161032$301,400.00 New Machine 200.00556180.00161032$5,591.40 Total Operating Cost of Phoenix and New Machine $253,646.27
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Cost Analysis Continued Cycles / hrCycles / weekCycles / yearCycles / 5 years Extra Cycles without Chamfering 6.85548.1028501.28142506.42 Cost of Cycles without Chamfering $15.63$1,250.62$65,032.26$325,161.29 Cost of Cycles with Chamfering $12.82$1,025.87$53,345.13$266,725.66 Cost of New Machine $130,000.00 Annual Benefit of New Machine $48,753.73 Pay-Back Period 2.67<<5 Cost per Cycle Phoenix Chamfers $2.28 Phoenix without Chamfer $1.87 New Machine Chamfers $0.03 Percent Difference 17.97%
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Future Topics Chip removal Automation Enclosure More in depth stress analysis Further VNC analysis to ensure adequate part range and cycle time
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Questions? Contact Info: vrm0298@rit.edu
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Time Study Breakdown Test Conditions - Trial #2 1,500 RPM – Chamfer Motor 41 Teeth – Bevel Ring Gear 4 Revolution & 4-Start Cutter 0.75mm Total Cycle Time = 129 sec Total Chamfering Time = 13.4 sec Actual Chamfering Time = ~3 sec Tooth Cutting Time = 109 sec
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Max Torque Breakdown Test Conditions 1,500 RPM – Chamfer Motor 41 Teeth – Bevel Ring Gear 4 Revolution & 4-Start Cutter 0.75mm and 1.25mm Chamfer Depth Trial #1 = 41.0 in-lbf 0.75mm Trial #4 = 92.5 in-lbf 1.25mm Trial #5 = 95.6 in-lbf 1.25mm Trial #3 = Off Chart 1.25mm
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