Post on 23-Dec-2015
DETAIL DESIGN REVIEWOCTOBER 26TH 2012
Team P13656: L. Abatte, W. Fritzinger, P. Torab, K. Karauda
Project Management: Plan
Project Schedule
Design Proposal
Ultrasonic, self-contained unit
Design Proposal
http://prezi.com/kjnwnkg7awaz/ultrasonic-cleaning-system/?auth_key=30636a7d6cb66176bbd1c45f00a37499b77e2f32
Specifications
Specifications
Coating & Extrusion Die Compositions
SS 400
Honeycomb Extrusion Dies TiCN (coating)
carbon 0.05 silicon 1
Manganese 1 chromium 12
phosphorus 0.03 aluminum 0.25
sulfur 0.03 iron 85.64
Reaction Equations Set Up
Define the underlying reactions Obtain redox potentials and equilibrium
constants for perspective reactions Developing the reaction rates & heat
generated by the exothermic reaction Utilize non-linear reaction program
analysis to generate reaction scheme Define optimization based on reaction
scheme
Reaction Sets
Redox Reactions Decomposition of H2O2 Acidic Stabilization Ti Redox reactions
From US Patent 20070023943
Variable Stripping Parameters
Validation Test Samples
Bar Stock Dimensions cross-section: square 2in x 2in thickness: 0.5 in
Capillaries: 9 units, 1/16 in Coating: TiCN Body: 316 SS
Sample Picture
Variable Test Samples
Panel Dimensions Length = 2 in Width = 2 in Thickness = 0.025 in
Coating: TiCN Body: 304 SS
Variable Test Sample
Sample Denotation FREQUENCY: 2 samples TEMPERATURE: 4 samples COMPOSITION: 4 samples FINAL/SPARES: 5 samples
Total: 15 Samples
Polarization Cell Components Test Sample Two Auxiliary Electrodes Luggin Capillary Salt Bridge Connection Inert Gas Connections Thermometer Glass Container
Functionality of Polarization Cell Adjusting potential of auxiliary electrode
1 to match the potential of the sample. Measuring the current flowing across the
other auxiliary electrode 2 and sample. Reference current flowing between the
two auxiliary electrodes. Generation of a Taffel plot Taffel plot deduced corrosion rate
[mass/time]
Prototype Testing
At this time there would be defined test conditions along with a prototype system.
The test will act as a check to the validation testing and variable testing.
Coated mini-dies will be used in the testing.
Reaction check
Supply & Cost Analysis for Testing
Pugh ChartConcepts
Criteria Updated Vert Rotary Ultrasonic HorizontalA Cost + 0 - +B Return on investment 0 0 + 0C Ease of use + - - +D Availability 0 - + 0E Maintenance + 0 0 +F Corrosion resistance + + + +G Fatigue - + 0 +H Lifetime 0 + + +I Aesthetics 0 + + +J Performance 0 0 + 0K Safety 0 0 0 0L Ergonomics + 0 + +
Sum + 5 4 7 8Score Sum 0 6 6 3 4
Sum - 1 2 2 0
ConceptsUpdated Vert Radial Ultrasonic Horizontal
Sub
Fun
ctio
ns
1Create flow over entire
surfaceMove parts in a vertical motion
Move parts radially
Ultrasonic vibration
Move parts in a horizontal
motion
2Create flow through
capillariesMove parts in a vertical motion
Move parts radially
Ultrasonic vibration
Move parts in a horizontal
motion
3Minimize chemical bath
degradation
Cover tank; limit contaminates around tank
Cover tank; limit contaminates around tank
Cover tank; decrease cycle
time
Cover tank; limit contaminates around tank
4 Maintain bath temperatureUse current
systemUse current
system
Heating system included in many
designs
Use current system
5Maintain homogeneous
mixtureKeep solution
agitatedKeep solution
agitatedKeep solution
agitatedKeep solution
agitated
6Reduce corrosive
environment exposure of system
Cover tank; redirect vapors
Cover tank; redirect vapors
Cover tank; redirect vapors
Cover tank; redirect vapors
7Increase corrosion
resistance of materials
Select corrosion resistant materials
Select corrosion resistant materials
Select corrosion resistant materials
Select corrosion resistant materials
8 Operating instructions
Prepare handbook containing graphics;
maintenance table;
documentation
Prepare handbook containing graphics;
maintenance table;
documentation
Prepare handbook containing graphics;
maintenance table;
documentation
Prepare handbook containing graphics;
maintenance table;
documentation
9 Protect Operator
Controls in safe spot; joints and
pinch points reduced; shielding
Controls in safe spot; joints and
pinch points reduced; shielding
Controls in safe spot; joints and
pinch points reduced; shielding
Controls in safe spot; joints and
pinch points reduced; shielding
10Limit exposure to
chemicalsCover tank;
redirect vaporsCover tank;
redirect vaporsCover tank;
redirect vaporsCover tank;
redirect vapors
Project Management: Risks
Risk Matrix
Bill of Materials - Rotational
Description Supplier P/N Unit Price Quantity Total Cost Supplier Owner Lead Time Status
Tank $0 1 $0.00 CTI CTI N/A Existing
NEMA 56 1/2hp wash-down motor 59845K68 $355.59 1 $355.59 McMaster - Carr Will In Stock Planned
High-efficiency speed reducer 6481K77 $247.15 1 $247.15 McMaster - Carr Will In Stock Planned
Corrosion resistant chain (1 ft.) 5960K1 $60.34 3 $181.02 McMaster - Carr Will In Stock Planned
Shielded thrust bearing 60715K15 $20.26 1 $20.26 McMaster - Carr Will In Stock Planned
Stainless steel shaft (1") 6526K55 $114.57 1 $114.57 McMaster - Carr Will In Stock Planned
Shaft collar (1") 9665T2 $68.65 1 $68.65 McMaster - Carr Will In Stock Planned
Drive sprocket (10 teeth) 6799K112 $50.25 1 $50.25 McMaster - Carr Will In Stock Planned
Driven sprocket (24 teeth) 6799K127 $99.80 1 $99.80 McMaster - Carr Will In Stock Planned
316 SS rectangular bar stock (6ft.) 9083K11 $74.12 1 $74.12 McMaster - Carr Will In Stock Planned
Polycarbonate sheet (12"x36"x1/8") 8574K265 $32.48 1 $32.48 McMaster - Carr Will In Stock Planned
Rotational System
Rotational System
Rotational System
Bill of Materials - Ultrasound
Description Supplier P/N Unit Price Quantity Cost Supplier Owner Lead Time Status
6 Gallon Cleaning Unit SC-6 $3,462.00 1 $3,462.00 Severe Clean Peter TBD Planned
Design Validation
Preliminary Testing: Necessary Equipment:
Small size ultrasonic tank Square test pieces:
2 x 2 in 316 steel (0.50 in thick) Coating: TiC, TiN, TiCN (since the exact coating
of the actual parts cannot be disclosed) Optionally: HSS drill bits can be used as test pieces
(coated with TiN) H2O2 bath (composition equal to the one used
by the customer)
Design Validation
Procedure: Test pieces will be weighed and the initial weight will be
recorded (prior to and after coating) Test pieces will be submerged in the tank Throughout the duration of the test, steel will be removed from
the tank several times and weighed. This will provide the data necessary for establishing the rate at which the coating is being stripped from the parts by the bath.
Test will also provide the data for establishing the bath degradation rate since the ultrasonic tank will be at different pressure and temperature compared to the current setup.
Testing will be conducted for several test pieces to provide reliable data and avoid measurement error.
Once the data is obtained it will be analyzed and presented to the customer as well as faculty guides.
Design Validation
Variables: Frequency:
What value is optimal? Range of acceptable values
Temperature: Natural convection: temperature gradient
throughout the tank (visit to vendor -> investigation) Solution composition Vibration intensity/ transducer strength Cavitation strength Jamestown Advanced demo
Design Validation
Vendors: McMaster Carr for sheet metal/ steel pieces Vergason for coating of the test pieces All machining can be done in house utilizing
the ME machine shop
Optional
In the future the design can be further expanded: Level switch Secondary
containment tank Piping system for
fluid recycling purposes
Questions?