wavertree pillar palm
DESCRIPTION
Wavertree Pillar Palm. Presented By: The University of Wisconsin Platteville Senior Design. The Design. Solidworks drawing of cast part after adding the parting line modifications to the bottom cylinder. The Design. Rivet Holes. Chamfer & Step. - PowerPoint PPT PresentationTRANSCRIPT
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Wavertree Pillar PalmPresented By:
The University of Wisconsin PlattevilleSenior Design
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The Design
Solidworks drawing of cast part after adding the parting line modifications to the bottom cylinder
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The Design
Solidworks drawing of final product after all steps completed
Rivet Holes
Chamfer&
Step
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Project Photos
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Pattern Design
• Mastercam drawing of pattern assembly
• Core (lower half), Pattern (upper half)
Core
Pattern
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Project Photos
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Tool Path for Machining
Tool paths for final machining of part
Tool paths for machining cope half
of pattern
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Project Photos
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Tool Path for Machining
Start of machining program for cope of pattern as shown in
Mastercam
End of machining program for cope of pattern as shown in
Mastercam
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Solidification Modeling(MagmaSoft Program)
Video of Solidification in
MagmaSoft
Niyama criterion in MagmaSoft
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Solidification Modeling(MagmaSoft Program)
Video of mold being filled using Magma
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Machining Pattern
Machining program for location holes
as shown on the 2-axis CNC mill
Machining program ½ done for cope of pattern as shown on the 4-axis CNC
mill
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Machining Pattern
Program near finished for cope of pattern on 4-axis
CNC mill
Cope of pattern finished on 4-axis
CNC mill
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Machining Pillar Palm
Fixture for machining step on
bottom of part.
Fixture for machining step on bottom of part with
part on it.
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Drilling Rivet Holes
Fixture for machining holes in
palm with part being machined
½” endmill milling holes after drilling
operation
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Machining Chamfer and Step
Chamfer on bottom of part being
machined
Step on bottom of part being machined
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Project Photos
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Gating and Riser Design
Foseco Riser
Pillar Palms
Gating
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Gating and Riser (Cross Section)
Pillar Palms
Foseco Riser
Gating
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Project Photos
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Solidification Modeling(Solidcast Program)
Shows how casting solidifies after pour
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A27 Steel Chemical Composition
• Required 5 test pours to obtain correct composition–5 test heats = 663 pounds of steel
• 14 Heats total = 1848 lbs melted• Composition
–Equivalent to Mild Steel• 0.192% Carbon (C)• 0.974% Manganese (Mn)• 0.794% Silicon (Si)
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Personal Protective Equipment
• Hard hat with shield• Safety glasses• Aluminized jacket• Aluminized apron• Aluminized spats (cover legs and ankles)• Aluminized gloves • Steel toed shoes
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PPE Required For Grinding
• Hard hat with shield• Ear plugs• Safety glasses• Flame resistant jacket
• Steel toed shoes
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Coordinate Measurement Machine
• Inspected prototype• Made positioning fixture• Visited “Stainless Foundry and
Engineering” for consulting• Measured each
casting for tolerances
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Coordinate Measurement Machine
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• Centerline – center hole to center hole
• Distance betweenhole and centerline
• Degree of anglefrom center ofhole to centerline
Measurement Points
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Project Photos
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Tensile Bar Testing• Made keel blocks• Machined tensile bars• Pulled tensile bars tests
–Tensile strength–Yield strength–Elongation
• Results–All parts met specification
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Project Photos
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Donations Make the Difference
Cost: Purchased vs. Donated
71%
29%
Donated Purchased
Without donations this project would not be possible
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Thank You to our Donating Companies
J. B. DeVENNE
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Project Photos
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Overhead Costs• Sand mixer and self centering vice• Increased mold making and machining efficiency
• Sand mixer - $30,000• Vice – complete donation
Overhead CostsItem Cost
Sand Mixer $ 8,000.00 Self Centering Vice $ 2,733.00
Grand Total $ 10,733.00
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The Breakdown
Cost Per Unit (Sand Mixer, Labor, Vice included)Cost Totals
Donated $ 4,355.15
Purchased $ 1,755.81
Labor $ 68,600.00
Sand Mixer $ 8,000.00
Grand Total $ 82,710.96
Cost Per Part $ 2,067.77
All costs included
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• No sand mixer, vice or labor included in total cost–Platteville students are free labor
The Breakdown
Cost Per Unit (No Labor Included)Cost Totals
Donated $ 4,355.15
Purchased $ 1,755.81
Grand Total $ 6,110.96
Cost Per Part $ 152.77
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Project Photos
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Facts and Figures• Resources Consumed• 8000 pounds of sand• 1800 pounds of slitter scrap (steel)
• Over 2500 man hours• $1800 in purchased goods• $4400 donated by outside
firms
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Project Photos
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Project Photos
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Project Photos
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Thank You• Dr. Kyle Metzloff Ph D.
–IS 4610 Professor• Ray Monroe
– Steel Founders Society (SFSA)• Philip Harrison
– Penumbra Design• Benji Johnson
–Magma Soft• Greg Gauerke
–Perfect Pattern – Core Box Build• Scott Sharpee
–Neenah Foundry
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The University of Wisconsin Platteville
Thanks you for your support