final project presentation (3rd year) - copy
TRANSCRIPT
THIRD YEAR PROJECT FINAL PRESENTATIONTHE MAUFACTURE OF A PYRAMID TYPE SLIP ROLLS
BY
Joseph Stynes X00105837
Project supervisorTom Healy
1/ The rollers are positioned in a pyramid configuration2/ The top roller is vertically adjustable3/ Two bottom feed rollers rotate in the same direction
What is a pyramid type slip rolls ???
Feed rollers
Top feed rollerMaterial being
rolled
Original concept sketch for pyramid type slip rolls
Original concept design
Development of final design
Four phases of manufacture
1/ Cutting of all materials to specified dimensions2/ Machining all components to specified dimensions3/ Fabrication and Welding4/ Assembly
Commencement of manufacture
Manufacturing of components
Assembly of finished components
Final assembly of finished components
Commencement of testing phase of project
Testing criteria1/ Testing of a range of different materials2/ Testing of a range of different thicknesses of materials3/ Theoretical testing of machine using the formulae for simple bending theory4/ Practical testing of machine using a range different materials in various thicknesses5/ Establishing whether the theoretical testing is validated by the practical testing6/ Record and tabulate practical testing results
Sample theoretical calculation using bending theory formulae
Mild steel
b = 0.5m / d = 0.003m / y = 0.0015m / Yield (Ο) = 210mPa
I = πππ πππ ππ π°= (π.ππ)π(π.πππ)πππ ππ π°= ππππ π ππβππππ
ππ= π΄π° so M = ππ π π° ππ π΄= πππ π ππππ΅ππ.ππππ π π ππππ π ππβππππ
Therefore M = 157.5 Nm
M = ππ π π.πππ so M = 0.02F so F = π΄π.ππ so F = πππ.π π΅ππ.ππ π
Therefore F = 7875 N
Table of results for practical testingTABLE OF RESULTS FOR THE TESTING OF THE FUNCTIONAL LIMITS OF PYRAMID TYPE SLIP ROLLS
TESTS MATERIAL b (m) d (m) Y (m)FEED ROLLER CENTRES
(m)POINT OF MAXIMUM BENDING
(m) S.M.O.A I (m^4) YIELD STRENGTH Ο (Pa)MAXIMUM BENDING MOMENT
(Nm) FORCE (N) STATUS
TEST 1 STEEL 0.5 0.001 0.0005 0.08 0.04 4.16667E-11 2.10E+08 17.5 875 PASS
TEST 2 STEEL 0.5 0.002 0.001 0.08 0.04 3.33333E-10 2.10E+08 70 3500 PASS
TEST 3 STEEL 0.5 0.003 0.0015 0.08 0.04 1.125E-09 2.10E+08 157.5 7875 PASS
TEST 4 STEEL 0.2 0.004 0.002 0.08 0.04 1.06667E-09 2.10E+08 112 5600 PASS
TEST 5 ALUMINIUM 0.15 0.002 0.001 0.08 0.04 1E-10 1.25E+08 12.5 625 PASS
TEST 6 ALUMINIUM 0.1 0.002 0.001 0.08 0.04 6.66667E-11 1.25E+08 8.33E+00 416.667 PASS
TEST 7 COPPER 0.1 0.006 0.003 0.08 0.04 1.8E-09 2.68E+08 160.8 8040 PASS (AT LIMITS)
Finished rolled test pieces
Compliance with project deadlines according to the manufacturing plan
MANUFACTURING PLAN FOR PYRAMID TYPE THREE ROLL SLIP ROLLSCOMPONENT MANUFACTURING PROCESSES TIME TAKEN (Hours) WEEK STATUS
RHS BASE FRAME CUTTING, DRILLING, WELDING 2 14 CompletedTHREADED INSERTS FOR RHS FRAME CUTTING, DRILLING, TAPPING, WELDING 2 14 Completed
IDLE END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 15 CompletedGEAR END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 16 Completed
TOP ROLLER CUTTING, TURNING, 4 16 CompletedBOTTOM FRONT FEED ROLLER CUTTING, TURNING, MILLING 6 17 CompletedBOTTOM BACK FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed
GEAR KEYS FOR BOTTOM FEED ROLLERS CUTTING, MILLING, FILING 4 17 CompletedINTERMEDIATE GEAR SHAFT CUTTING, TURNING, MILLING 2 18 Completed
INTERMEDIATE GEAR SHAFT KEY CUTTING, MILLING, FILING 1 18 CompletedBRASS TOP ROLLER GUIDES CUTTING, DRILLING, FILING, MILLING 6 18 CompletedBOTTOM LOCKING BLOCKS CUTTING, DRILLING, COUNTERSINKING 4 18 Completed
TOP LOCKING BLOCKS CUTTING, DRILLING, COUNTERBORING 4 18 CompletedTHREADED ROUND SCREWJACK GUIDE CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed
SCREWJACK TURNING HANDLES CUTTING, WELDING 2 19 CompletedSCREWJACK TURNING HANDLE BODIES CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed
RETAINING RING FOR BRASS GUIDES CUTTING, DRILLING, WELDING 2 19 CompletedTHREADED ROD CUTTING 1 19 Completed
CRANKING HANDLE CUTTING, DRILLING, WELDING 2 19 CompletedCRANKING HANDLE BOSS CUTTING, DRILLING, FILING,WELDING 2 19 Completed
PRESSING BEARINGS HYDRAULIC PRESSING 1 19 CompletedASSEMBLY ASSEMBLING OF COMPONENTS AND TORQUEING OF BOLTS 4 20 Completed
TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 21 CompletedTESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 22 Completed
The finished manufactured artefact
Thank you for listening
Any questions ???