matt baum design engineer portfolio
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- 1. Engineering Design Matt Baum
- 2. Matt baum I want to be a part of designing the future and conceiving new ways for us to thrive in the 21st century. In my work I seek to combine an understanding of function and mechanics with an appreciation of form and beauty that I have cultivated through my studies of both engineering and design. I have developed the skills to engage in every stage of product development. I enjoy design research, product ideation and sketching, 3D modeling and rendering, and prototyping and manufacturing. I am excited and inspired by the innovation taking place at the heart of design culture in areas like renewable energy and sustainable design, new forms of transportation and urban planning, and human-centered products that connect us to our technology and to each other. My goal is not merely to produce and sell more consumer goods, but to create meaningful new ways for people to live and societies to function.
- 3. Contents Machine Design Machined Aluminum Motor Mount Sheet Metal Motor Mount Injection Molded Nylon Motor Mount DVD Return Slot Assembly Product and Business Design Modgardens Prototyping Heavy Lift Octocopter 3D Printed Impeller Social Design Circular Production Toyota Production Stages A Nation in Crisis Resume
- 4. machine design Solidworks 3D Modeling Design for Manufacture Mechanical Systems Design 2D Part Drawings GD&T motor mount part design These motor mounts were designed in a machine design class to gain experience with design for manufacture. Three different motor mounts were designed based on the manufacturing technique: machining, sheet metal, and injection molding. Each part model took into account the manufacturing steps necessary to produce the design. The assembly models are toleranced based on GD&T standards. The motor mount was designed to fasten the motor of an archive data storage system to a flat tray surface to maintain proper gear alignment. The primary functions of the motor mount are to: a) rigidly support the motor shaft bearing (aligns motor to gears) and b) incorporate two bearing holding tabs.
- 5. machined aluminum Design The design has a thick front surface that is fastened to the shaft alignment part on either side of the motor shaft bearing, providing reliable alignment and stability to the motor. Two pins on opposite corners of the part serve to position the motor mount relative to the shaft alignment part. The hole and slot that accommodate these pins are drilled blind but are designed with generous depth tolerance. Fastening the motor mount to the shaft alignment part using two screws on the sides of the part (in addition to the fastener on the corner flange) avoids the excessive material removal that would be required to fabricate flanges for an entirely top-down assembly. Manufacturing The motor mount requires 4 different machining directions and begins with a 1.5in3 block of solid aluminum. Direction 1: Bottom Surface -Grind surface to 1.117in -Remove material using a 1/2in tool -Mill pin holes using a .093in tool and drill clearance hole for fastener using a #5 drill bit Direction 2: Front Surface -Drill holes using 5/32in drill bit. Bore center hole to 0.189in to accommodate motor shaft -Mill flange using 5/64in tool Direction 3: Right Surface -Grind surface to 1.354in -Mill flange using 5/64in tool -Mill corner tab using 5/64in tool -Drill fastener clearance hole using #5 drill bit Direction 4: Back Surface -Grind surface to 1.437in -Drill fastener clearance hole using #5 drill bit -Mill cutout using 5/64in tool Analysis Deflection at load: =(Fl^3)/3EI h^3=(4Fl^3)/Eb h^3=(4(75lb)(0.478in)^3)/ (10e6psi(0.315in)(0.0118in)) h=0.096in Bending Stress: =(Fl h/2)/I =6Fl/(bh^2 ) =(6(75lb)(0.478in))/((0.315in) (0.096in)) =29638psi Tensile yield strength of aluminum 6061-T6 is 40,000psi. Assuming a deflection of 0.0118in (based on deflection of previous part) and using a tab thickness of 0.096in resulted in an applied force of 75lbf and a bending stress of 29,638psi. This is well under the tensile yield strength of 40,000psi. Back view of motor mount
- 6. sheet metal Design The chosen design is simple and efficient, using a minimal amount of folds and material. Flanges were created to accommodate the pins and fasteners, and tabs were created to hold the bearings in place. The tabs have a spring- like form to maximize their ability to withstand deflection. A vertical tab of material directly below the motor shaft bearing serves as a datum feature and maximizes the accuracy of the bearing positioning. A pin and slot on opposite corners of the part serve to position the motor mount relative to the shaft alignment part. Two M2 SHCS screws are used to fasten the motor mount to the shaft alignment part. The part is stamped from a 63mm x 83mm sheet of 16 gauge (1.651mm) steel and folded into shape. Manufacturing Part begins with a 63mm x 83mm sheet of 16 gauge steel. Flat pattern can be nested with spring tabs overlapping to save material. 1. Stamp or laser cut 63mm x 88mm sheet to form flattened shape of part. 2. Pierce fastener holes, sized to fit 1/16 dowel pins and M2 fastener screws. 3. Fold sheet into final form of part (possible order: a) 2 folds to form 3 base sheets that accommodate motor b) fold positioning and securing tabs c) fold spring tabs. 4. Touch up and finishing. Remove sharp edges. Analysis 1. The tab structure was simplified by considering the horizontal distance of the bent tab to be the effective length. 2. Initial tab model experienced a total deflection of 0.254 mm. 3. Goal seek was used to deter- mine the force needed to match this assumed deflection. 4. The force needed, 56 lbs, caused yielding in first iteration of the spring tab. 5. Length of tabs was adjusted to reduce deflection. 6. Stress analysis was done on each individual tab to insure yield- ing does not occur. Result: to reduce stress on the tabs, the tab lengths were adjusted to produce 34.2 lbs of force with a total deflection of 0.115mm. Motor mount installed in assembly to secure motor shaft and bearings
- 7. injection molded nylon Design The chosen design has a curved nominal wall that follows the form of the motor shaft to reduce the size of the part and the material used. The tabs that accommodate the fasteners and hold the bearings in place are projections off of the curved nominal wall. The curved nominal wall and the tab projections are designed with a uniform thickness to facilitate an even injection of material. Fillets have been added to all of the sharp corners of the part to make them easier to fill and avoid high molded- in stresses. Ribs were incorporated into the tabs to add support and rigidity. Two pins are built into the tabs on opposite corners of the part to position the motor mount relative to the shaft alignment part. Analysis The deflection of the tab was computed using a cantilever-end load condition, and the stress of the tab was calculated using the bending stress equation. A tab deflection clearance of 0.020 was assumed in order to calculate the corresponding force needed. The material chosen for this part was Nylon. The Nylon has a yield strength of 12 ksi. The maximum stress the tabs will have is 10.5 ksi, so the tabs should not fail. Manufacturing The core half of the mold forms the underside of the curved motor enclosure and creates the bottom features of the part (colored in green), and the cavity half of the mold forms the top features (colored in blue). The gate is located in the center of the top surface of the curved enclosure, since this surface is the nominal wall and the central location of the gate will allow an even flow of material into the projected walls. A side action is used to create the cutouts for the clearance hole where the motor mount attaches to the motor, and for the hole that accommodates the motor shaft bearing. The inside surface of the part has a 2 degree draft angle to allow a smooth separation of the core and cavity, and the ribs have a 1 degree draft angle. Motor mount installed in assembly to secure motor shaft and bearings
- 8. DVD REturn slot assembly The DVD Kiosk Return Slot is designed to accept a DVD returned by the user. It feeds the DVD back into the machine to a point where a picker can grab it and file it into the correct location within the machine. The Return Slot is mounted on the inside of the overall DVD Kiosk and is only visible by its very front slot where the user returns the DVD. The design uses a drive system consisting of two shafts driven by one stepper motor to move the DVD along its intended path. Two gates within the Return Slot interpret signals from the electronics system that determine whether or not the DVD will be accepted into the drive system. Most of the parts were obtained from McMaster Carr. Part drawings are included for the parts that have been custom designed and must be manufa
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