1. Jump to first page n Team Members:  Katie Kaser - Introduction & Concept Generation  Moshe Solomon - Concept Selection  Joanna Pirnot - Concept Development  Lihong Xu - Budget Sponsor: Fraunhofer USA Advisor: Dr. Michael Keefe TEAM 11 ULTRASONIC MIXER

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3. Mechanical Mixers Size Cost Wear Contamination Maintenance

4. Jump to first page Mission Design a non-mechanical mixer for homogenizing powder injection molding feedstock by April 1999 Approach : u Identify wants and constraints u Benchmark previous technology u Generate set of concepts u Select best concept u Execute design via best engineering methodology

5. Jump to first page Customers n Sponsor - Fraunhofer n Mixer suppliers u Misonix Inc. n Ultrasonic consulting companies u Advanced Sonic Processing Systems n Anyone involved in powder injection molding

6. Jump to first page Wants & Constraints Top 5 Wants u Temperature Control u Low Contamination Level u Ease of cleaning u Cost u Produce measurable quantity Constraints u Completion by April 1999 u Produce homogenous mixture u Safety

7. Jump to first page System Benchmarking n Mechanical Mixers n High Shear Mixers u Static mixer u Pump/internal obstacle mixer (Sonolater) Ultrasonic Mixers u Probe-type u External sound source

8. Jump to first page Metrics n Want u Temperature control u Low contamination level u Handle variety of materials n Metric u Temperature control range u Percentage contaminants u Viscosity range

9. Jump to first page Functional & Ultrasonic Benchmarking n Functions u Feeding u Heating u Mixing u Cooling n Ultrasonics u Ultrasonic Generators u Transducers

10. Jump to first page What did we learn? n Ultrasonics is a significant source of heat n Heating and mixing should be as concurrent as possible n A system incorporating a probe is subject to contamination and wear on the probe n More energy reaches the material to be mixed using a probe than transmitting through walls of a vessel n Ultrasonics are capable of mixing solid powders in a polymer resin. u On the macroscopic level a homogenous mixture was achieved

11. Jump to first page Target Values n Metric u Temperature control range u Volume loading metal powder u Ease of cleaning n Target Value u 0 to 200 degrees C u 60% u Time to Disassemble

12. Jump to first page Critical Functions n Feeding n Heating n Mixing n Cooling/Removal

13. Jump to first page Concept Generation n Rotating Mixer n Opposing Sound Sources n Probe-type ultrasonic mixer n Separate heating/mixing chamber n Hexagonal tube mixer

14. Jump to first page Concept 3: Rotating Mixer

15. Jump to first page High Intensity Ultrasonic Processor

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17. CONCEPT SELECTION S S D R E S U L T S CONCEPTS WANTS METRICS TARGET VALUES1 2 3 4 5 SUITABLE TEMPERATURE AVOID CONTAMINATION DUE TO ABRASION AVOID CONTAMINATION DUE TO AN EXTERNAL SOURCE EASY TO CLEAN VARIETY OF MATERIALS REASONABLE COST PRODUCE A MEASURABLE QUANTITY OF MATERIAL REPEATABLE PERFORMANCE PRODUCE FEEDSTOCK IN USABLE FORM AVOID WASTE MATERIAL WHEN CLEANING CONTROLED FEEDING MECHANISM TEMPERATURE OF THE MATERIAL BEING MIXED % CONTAMINANTS IN THE PRODUCT % CONTAMINANTS IN THE PRODUCTS ABILITY TO DISASSEMBLE, CLEAN BY HAND, & KEEP WARM WHILE CLEANING VISCOSITY COST MUCH LESS THAN A MECHANICAL MIXER OUTPUT / HOUR RELIABILITY GEOMETRY OF THE PRODUCT % OF MATERIAL LOST % OF MATERIAL LOST 0 TO 200 DEGREES CELSIUS LESS THAN 3% 0 TO 100 DEGREES CELSIUS 0 - 1000 Pa-s LESS THAN $5000 GEATER THAN OR EQUAL TO 5 LBS/HR LOW STANDARD DEVIATION IN MIXING RESULTS PELLET OR SPHERICAL SHAPE LESS THAN 5% 0% 15255555245551525555524555 43434421342334343442134233 44434421343434443442134343 43423421242334342342124233 54434421545445443442154544

18. Jump to first page Concept Selection Evaluation of Wants (Scale 1-5, 5 being the highest score) n 1st (probe type mixer) - 54 pts n 2nd (opposing sound sources) - 40 pts n 3rd (rotating mixer)- 43 pts n 4th (separate heating and mixing) - 37 pts n 5th (hexagonal tube mixer) - 49 pts

19. Jump to first page CONCEPT SELECTION CRITICAL FUNCTIONS FEEDING  Automatic Feeder Unit  Trough HEATING  Double Walled Vessel with Inlet and Outlet for Water Circulation  Heat Exchanger Fluid Pumping System

20. Jump to first page CONCEPT SELECTION CRITICAL FUNCTIONS MIXING  600 Watt Ultrasonic Probe  Booster Horn REMOVAL / COOLING  Teflon Stopcock  Conveyor Belt  Collecting Pan

21. Jump to first page Concept Development n Demonstration (Video) n Test Results u Critical Functions u Prototype vs. Target Values n Modifications/Suggestions

22. Jump to first page Feeding n Capabilities u Automated feeder sufficiently transports powder to the mixing vessel n Limitations u speed of feeder u Residual amount of material remains on the surface of the funnel and feeder tubing

23. Jump to first page Heating n Capabilities u sufficiently melts materials with a low melting point  ex. Paraffin u sufficiently removes excess heat produced by ultrasonic processor u sufficiently keeps materials warm during removal n Limitations u the variety of materials (with a high melting pt.)  ex. Polypropylene u temperature range 0 to 100 degrees Celsius  due to probe limitations u the heating fluid (water) is incapable of temp. higher than 100 degrees Celsius

24. Jump to first page Mixing n Capabilities u Solids Loading F Original Design 20% solids loading F Shape of the vessel 35% solids loading F Shape of vessel and Booster Horn 60% solids loading u Product F Satisfactory homogeneity microscope examination melting (consistency) capillary rheometer u No degradation of polymer of deposits of powder n Limitations u Volume no greater than 50ml  splashing occurs u Amplitude of the Horn must be 65%  splashing occurs u Variety of materials F only soft materials, otherwise erosion of the tip occurs

25. Jump to first page Removal of Material n Capabilities u regulating flow of the material  flick valve u material is removed within 2 minutes u no excess heat is required u 96% of material is recovered F prior to cleaning n Limitations u If the flow is too slow, material tends to solidify prior to exiting the vessel

26. Jump to first page Cooling n Capabilities u material does not solidify prior to contact with the conveyor belt u Air cooling is a sufficient method of cooling feedstock u the material is in a usable form n Limitations u conveyor belt must be set horizontally F material flows too quickly u speed of conveyor belt must be on the lowest setting F material not cooled upon reaching the end of the conveyor belt

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28. Modifications/Suggestions (addressing our limitations) Feeding u use spherical shaped powders n Heating u purchase an air cooling converter F allows probe to safely reach higher temperatures u use a fluid capable of reaching a higher temperature

29. Jump to first page Modifications/Suggestions Mixing u purchase a larger vessel to increase the output/hour (no greater than 250ml batches - probe tip (1/2 diameter) u purchase a larger probe tip - 1in diameter (capable of mixing volumes up to 1000ml) u coat the tip of the probe with tungsten carbide  this will reduce the erosion of the titanium tip

30. Jump to first page Removal u Apply heat to the nozzle area to eliminate faster cooling of material; use heating gun Cooling u Use longer conveyer belt; current length insufficient for air-cooling of larger pelleted feedstock

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33. Budget All Budgeted Material and Equipment Expenditures Estimated Upgrade Cost Engineering Development Time Conclusion

34. Jump to first page Projected Production Cost: $15520.99 Total cost for the project: $520.99 All Budgeted Material

35. Jump to first page Estimated Upgrade Cost Total upgrade cost: $6670.99 $50K to $70K $6700

36. Jump to first page Engineering Development Time Fall 10 hr/person/week for 13 weeks Winter 4 hr/person/week for 4 weeks Spring 12 hr/person/week for 10 weeks (include testing time 4hr/person/week for 6 weeks) Total time: 1064 hours

37. Jump to first page In Conclusion... A great team gained experience from the opportunity to use engineering theory in a practical way, developing an innovative technology solution meeting the specific real-world wants of our industrial customer...