Senior Design Team 05:

Gleason Works – Chamfering and Deburring

Project

Critical Design Review

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 $130k Cycle time under 1 minute As many commercial parts as possible Decrease footprint

Deliverables Top level ProE 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

Time Study Cycle (Trial #2)

0

0.5

1

1.5

2

2.5

3

3.5

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

Time (s)

Vo

lts

(V)

Cutter

Chamfer

Repeated Cycle for 41 Teeth

Cycle starts at 0.4 secDoor Closes

Cycle stops at 129 secDoor Opens

Cutter disengages andChamfer starts up

Peak value of voltage corresponds to Trial #1

Max Torque CurveVolt & Torque

0

20

40

60

80

100

120

0 0.5 1 1.5 2 2.5 3

Time (s)

To

rqu

e (i

n-l

bf)

Trial 1

Trial 4

Trial 5

Trial 3

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 20800 20800

Cost per Hour $32.45 $32.69 $6.25

Man Power per Hour $40.00 $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

Cost of Cycles with Chamfering

$12.82 $1,025.87 $53,345.13 $266,725.66

Cost of New Machine $130,000.00

Annual Benefit of New Machine $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: vrm0298@rit.edu

Time Study Breakdown Test Conditions - Trial #2

1,500 RPM – Chamfer Motor 41 Teeth – Bevel Ring Gear 4 Revolution & 4-Start Cutter 0.75mm

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 0.75mm and 1.25mm Chamfer Depth

Trial #1 = 41.0 in-lbf 0.75mm Trial #4 = 92.5 in-lbf 1.25mm Trial #5 = 95.6 in-lbf 1.25mm Trial #3 = Off Chart 1.25mm