Critical Design Review Senior Design Team 05 Gleason

Critical Design Review Senior Design Team 05: Gleason Works – Chamfering and Deburring Project

Team Introduction ® ® ® ® ® Project Manager: Vincenzo Mansueto -ME Lead Engineer: Matthew Liddick -ME Team Member: Brian Banazwski -ME Team Member: Mark Trotta -ME Team Member: Julie Wilcox -ME Team Member: Phil Raduns -EE Team Member: Greg Baesl -ISE Faculty Advisor: Bill Scarbrough Gleasons Representative: Eric Mundt

Company Background Leading world-wide supplier of gear cutting technology ® Subdivision of Gleason Corporation ® Primary Market ® Automobile and truck industries ® Secondary Market ® Aerospace, Farm, Construction, Marine ®

Defining the Need ® Cutting process for creating gears leaves behind sharp edges and burrs ® ® ® Danger to workers Gear strength Contamination Aesthetic Two current processes need improvement or modification

On Machine Apparatus ® Not capable of tilt in both directions ® Has no scrapper ® Burrs still exist after chamfer

GTR 250 ® Too slow ® 30 rpm max on work spindle ® Too expensive ® Accuracy of machine is excessive for process ® Large footprint

Design Requirements and Deliverables ® Requirements ® Chamfer and deburr in same cycle ® Capable of machining various sizes of gear sets ® Price below $130 k ® Cycle time under 1 minute ® As many commercial parts as possible ® Decrease footprint ® Deliverables ® Top level Pro. E drawings ® Market assessment

Design Proposal ® ~70% smaller foot- print than GTR ® More tilt capabilities than both existing ® Lower cost

Process Demonstration

How we arrived at our design ® Work Break-down Structure Cutting Tool Apparatus ® Work Piece Apparatus ® Stock Divider ® Electronics ® Enclosure ® ® Customer Interactions ® Current process investigations

Tilt Structure

Stock Divider

Time Study

Max Torque Curve

Electrical Components ® Servo/Spindle Motors ® Drives ® CNC Controller

Cost Analysis Phoenix Stand Alone Phoenix with Chamfering unit New Chamfering Machine Cost of Machine $675, 000 $680, 000 $130, 000 Hours Operated 20800 Cost per Hour $32. 45 $32. 69 $6. 25 Man Power per Hour $40. 00 $0. 00 Total Cost per Hour $72. 45 $72. 69 $6. 25 Cycle Time Seconds Hours Cycles per Hour Cycles per Year Cost per Year Phoenix with Chamfering 113 0. 03139 31. 86 132531 $302, 400. 00 Phoenix without Chamfering 93 0. 02583 38. 71 161032 $301, 400. 00 New Machine 20 0. 00556 180. 00 161032 $5, 591. 40 Total Operating Cost of Phoenix and New Machine $253, 646. 27

Cost Analysis Continued Cycles / hr Cycles / week Cycles / year Cycles / 5 years Extra Cycles without Chamfering 6. 85 548. 10 28501. 28 142506. 42 Cost of Cycles without Chamfering $15. 63 $1, 250. 62 $65, 032. 26 $325, 161. 29 $12. 82 $1, 025. 87 $53, 345. 13 $266, 725. 66 Cost of Cycles with Chamfering Cost of New Machine Annual Benefit of New Machine $130, 000. 00 $48, 753. 73 Pay-Back Period 2. 67 << 5 Cost per Cycle Phoenix Chamfers $2. 28 Phoenix without Chamfer $1. 87 New Machine Chamfers $0. 03 Percent Difference 17. 97%

Future Topics ® Chip removal ® Automation ® Enclosure ® More in depth stress analysis ® Further VNC analysis to ensure adequate part range and cycle time

®Questions? Contact Info: vrm 0298@rit. edu

Time Study Breakdown ® Test Conditions - Trial #2 ® 1, 500 RPM – Chamfer Motor ® 41 Teeth – Bevel Ring Gear ® 4 Revolution & 4 -Start Cutter ® 0. 75 mm ® Total Cycle Time = 129 sec ® Total Chamfering Time = 13. 4 sec ® Actual Chamfering Time = ~3 sec ® Tooth Cutting Time = 109 sec

Max Torque Breakdown ® Test Conditions ® 1, 500 RPM – Chamfer Motor ® 41 Teeth – Bevel Ring Gear ® 4 Revolution & 4 -Start Cutter ® 0. 75 mm and 1. 25 mm Chamfer Depth ® Trial #1 = 41. 0 in-lbf 0. 75 mm ® Trial #4 = 92. 5 in-lbf 1. 25 mm ® Trial #5 = 95. 6 in-lbf 1. 25 mm ® Trial #3 = Off Chart 1. 25 mm