DETAIL DESIGN REVIEWOCTOBER 26TH 2012Team 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/ultrasoni

c-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 SamplesBar 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 SamplesPanel 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

Func

tions

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 - RotationalDescription 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 ValidationPreliminary 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?