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Team Tie-Master Brittany Ballard Cam Leslie Steve May

Final Design. Tie-down Finishing Machine. Team Tie-Master Brittany Ballard Cam Leslie Steve May. Project Problem. Current Situation: Surface of aluminum tracks finished by-hand Burrs on edges from milling Chips from milling can get lodged in the channel of the track

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Team Tie-Master Brittany Ballard Cam Leslie Steve May

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  1. Final Design Tie-down Finishing Machine Team Tie-Master Brittany Ballard Cam Leslie Steve May

  2. Project Problem Current Situation: • Surface of aluminum tracks finished by-hand • Burrs on edges from milling • Chips from milling can get lodged in the channel of the track • Outer surface of the track is inconsistent

  3. Project Problem Current Issues: • Manual surface finish is time consuming • May pose health hazards

  4. Project Goal Design, fabricate, and test a machine that will automatically finish, de-burr, and clear debrisfrom several different tie-down track profiles

  5. Specifications

  6. Conceptual Design Broken into specific areas: Creating the Grain and De-burring Removing Debris Track Movement

  7. Detailed Design Creating the Grain and De-burring

  8. Detailed Design FEA with ABAQUS Stresses were calculated w/ various increasing loads until failure predicted at 300 lbf.

  9. Detailed DesignRemoving Debris

  10. Detailed DesignTrack Movement

  11. Detailed DesignCATIA Model The case footprint is 14.5”x14” This is the final design. The overall length is 4ft.

  12. Detailed DesignCATIA Model

  13. Manufacturing Processes • Milling and welding were the two processes most used for this project • Many parts were ordered from manufacturers • This will allow for easy replacement

  14. Final Product

  15. Final Product • Systems were tested separately • Each system met specs when tested separately • Systems are currently being integrated

  16. Total Cost Initial Budget of $ 4,000 Total cost ≈ $ 3,500

  17. Media Cost • Using the current setup, there are 2-6” pads and 4-5.6” pads in the finishing wheel stack • Cost of each pad is $2.58 ea • The pad stack can be used for approximately 200 ft of track, depending on the length of individual tracks Media cost = $15.48 for 200 ft of track = $0.08 per ft of track

  18. Working Hours • These hours include time for all group members (3) • This equates to approximately 15.5 hrs of work per week, per person on this • project

  19. Future Adaptations • Kaizen Projects • Make finishing pads last longer • Layout of Mac’s shop • Other Features • Adding a debris separator to funnel • Future use on other aluminum parts • Change placement of finishing pads for improved grain

  20. Questions?

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