Team FOAM Design Team 6

1. Team FOAMDesign Team 6 Advisor: Dr. Darrel Doman Client: Precise Designs Engineering Solutions Members: Fredrik Sy, DainisNams, Allison Chua, MotazTaha

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

3. Background Polyplank foam (www.casecad.com) • 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

4. Requirements

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

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

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

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

9. Testing Goals • 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. Quality Index (1) (2) (4) (3) • Qualitative scale to measure quality of cuts

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

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

13. Performance Results: CNC Foam Cutting Remaining Foam Cutting Increment Tool Path Pocket • 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

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

15. CNC Foam Cutting Video

16. CNC Foam Cutting: Example Product

17. Operational Parameters

18. Requirements Check

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

20. Conclusions • 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

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

22. 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

23. 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

24. 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.

25. 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.

26. Budget

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

28. Detailed Design Parameters • Budget : Spent $ 1 900 • Under budget by ~ $1 300 • Overall length ( to beginning of element) is 4.25 in.