process improvement for convoluted ptfe hose thermal …2016 process improvement for convoluted ptfe...

SENIOR DESIGN Spring 2016 Process Improvement for Convoluted PTFE Hose Thermal Expansion PROJECT SUMMARY TECHNICAL APPROACH Thermal Expansion Solutions was tasked to improve upon the existing process that Parker Stratoflex utilizes to thermally expand convoluted PTFE hoses for aerospace applications. Key requirements for the project where improved safety, reduced product scrap, increased process repeatability, and reduced overall process time. A new thermal expander was designed to address these requirements. The new design consists of four main areas: the hose-clamping mechanism, the rail system with support frame, mandrels with mandrel compartments, and the sliding trapdoor. Phase I • Investigated current thermal expander design and process. • Developed criteria to address key client needs for improved safety, reduced product scrap due to PTFE folding, increased process repeatability, and reduced process time per hose. • Developed potential solutions for improvementto key areas of the thermal expander and combined down-selected items into final conceptual design. Phase II • Fabricated test mandrels to determine best mandrel shape to expand hoses. • Developed detailed design with suggested improvements from client. • Established procedures for assembly, operation, and maintenance of new thermal expander design. • Presented finalized detailed design with recommendations for further development and automation. Ronaldo Marion Team Lead Ryan Serio Design Lead Joaquin Felix CAD Modeler Marcus Brewer Thermal Analysis Marc Sellers Materials Research Thermal Expansion Solutions Figure 1: Current thermal expander design. Figure 2: Expander PTFE Hose with Folding Defect. Figure 2: New Thermal Expander Design. Trapdoor, electric box, and ventilation equipment are not shown.

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Page 1: Process Improvement for Convoluted PTFE Hose Thermal …2016 Process Improvement for Convoluted PTFE Hose Thermal Expansion PROJECT SUMMARY TECHNICAL APPROACH Thermal Expansion Solutions

SENIORDESIGN

Spring

2016 ProcessImprovementforConvolutedPTFEHoseThermalExpansion

PROJECTSUMMARY

TECHNICALAPPROACH

ThermalExpansionSolutionswastaskedtoimproveupontheexistingprocessthatParkerStratoflex utilizestothermallyexpandconvolutedPTFEhosesforaerospaceapplications.Keyrequirementsfortheprojectwhereimprovedsafety,reducedproductscrap,increasedprocessrepeatability,andreducedoverallprocesstime.

Anewthermalexpanderwasdesignedtoaddresstheserequirements.Thenewdesignconsistsoffourmainareas:thehose-clampingmechanism,therailsystemwithsupportframe,mandrelswithmandrelcompartments,andtheslidingtrapdoor.

PhaseI• Investigatedcurrentthermalexpanderdesignandprocess.• Developedcriteriatoaddresskeyclientneedsforimprovedsafety,

reducedproductscrapduetoPTFEfolding,increasedprocessrepeatability,andreducedprocesstimeperhose.

• Developedpotentialsolutionsforimprovementtokeyareasofthethermalexpanderandcombineddown-selecteditemsintofinalconceptualdesign.

PhaseII• Fabricatedtestmandrelstodeterminebestmandrelshapetoexpand

hoses.• Developeddetaileddesignwithsuggestedimprovementsfromclient.• Establishedproceduresforassembly,operation,andmaintenanceof

newthermalexpanderdesign.• Presentedfinalizeddetaileddesignwithrecommendationsforfurther

developmentandautomation.

RonaldoMarionTeamLead

RyanSerioDesignLead

JoaquinFelixCADModeler

MarcusBrewerThermalAnalysis

MarcSellersMaterialsResearch