Vertical Struts. P16603: Work Piece Movement Jonathan Sanabria April 19, Contents

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1 Vertical Struts P16603: Work Piece Movement Jonathan Sanabria April 19, 2016 Contents Overview Assumptions for Research/Design Summary of Research Summary of Design Moving Forward Overview The primary function of the vertical struts is to provide a method for attaching the workpiece movement system to the other systems (guide roll system, etc.). The vertical struts also serve to vertically displace the workpiece movement system so that the workpiece can always sit above the guide rolls. Lastly, the vertical struts serve as tightly toleranced datums for the linear rails to be attached to. This provides a repeatable path for the entire vertical translation of the workpiece to take place. Thus, the vertical struts should be rigid and resistance to deflections (bending and axial). Assumptions for Research/Design In order to begin designing the vertical struts, some important initial assumptions had to be made. First, the general geometry of the struts was defined to be a rectangular extrusion. In other words, the struts would simply have three dimensions: thickness, width, and height (as well as some holes and other small features). However, in order to quantify each of the three critical dimensions, several different analyses needed to take place. First, after working with the guide roll team and realizing some different options for potentially mounting to the guide roll fixture, it was decided that three struts could be used: two on the workpiece loading side and one single one on the motorside of the guide roll system. Each of the struts would bolt directly to the angle plates used by the guide roll team since the angle plates could provide a flat, rigid mounting area. Since the angle plates have large gussets for structural support, the maximum width between the gussets would define the maximum width of the strut. The maximum width between

2 the gussets on the workpiece loading side was found to be 265mm while the maximum width between the gussets on the motor side was found to be 205mm. Moreover, on the loading side of the system, a workpiece would need to fit between the two inner edges of the struts. Since the workpiece would be manually loaded by the machine operator, a clearance would be needed between the edges of the maximum size workpiece and the strut edges. With this in mind, it was found that a strut width of 203.2mm (8 ) would leave nearly 38.1mm (1.5 ) on either side of the maximum size workpiece. Since 203.2mm was smaller than both of the constraints from the distances between the gussets, the width of all three of the struts could now be defined by this value. Next, the overall height of the strut needed to be defined. Ultimately the function of the height of the strut was to properly orient the entire system in the vertical direction above the guide roll system. Thus, some critical dimensions were needed to help define the overall height of the struts. Some of these critical dimensions could be altered (for instance, since the thickness of the translating plate was not yet defined, it would ultimately change the overall height of the struts) and were considered to be set dimensions. Set dimensions could be updated as the project progressed and then the overall height of the struts could then be updated as well. The following table shows the critical dimensions and their associated values (in mm) that dictated the height of the struts: Description Source Value (mm) Top of horizontal portion of angle plate to top of angle plate Given 590 Clearance Above Angle plate for loading Set 25.3 Workpiece Height Given 280 Mounting Plate Thickness Given 20 Dovetail (half) thickness Given 13.5 Dovetail Lip to Top of Fixture Mount Set 75.4 Translating Plate Thickness Set 50.8 Locking Mechanism Height/Motor height Set 150 Clearance Above Locking Mechanism to bottom of top plate Set 50 Height of Struts Calculated 1255 With the width and height of the struts now defined, only the thickness and material needed definition in order to complete the vertical strut design (plus holes for mounting). The thickness would be dictated by different failure modes of the vertical struts. More specifically, one would expect the struts to either fail from buckling under

3 the weight of the structure or from yielding due to the same hanging structural weight. In order to gather a better understanding about whether the hanging weight would cause failure in either mode, assumptions about the weight of the system was made. A list of the calculated or assumed weights for various parts of the system can be seen as follows: Component Weight (lb) Comments Workpiece 250 Quartz, 380X400X280mm Sacrificial Glass 4 Given from Glass Fab Mounting Plate and Dovetail 23 Given from Glass Fab Fixture Mount 110 Tool grade steel, calculated in Solidworks Translating Plate 377 A36 Steel Locking Mechanism 50 assumed based on some standard cylinders Linear Bearings 20 assumed (2 bearings) Extension Rods 25 L Brackets 10 Hardware 10 assumed Guide Rolls (each) 157 Given from P16601 Maximum Hanging Weight 786 Linear Rails 10 Electric Cylinder 40 Pneumatic Cylinders 80 Top Plate 872 Total Weight 1788 From the table, it can be seen that one would expect the struts to see a total weight of approximately 1788 lbs. Since the strut on the motor side would see half of this value (assuming all forces from hanging weight would act through a midplane between the two different sides motorside and loading side), 894 lbs (~4000 N), was used to see whether or not the strut on motor side and thus both sides would fail. First, it was found that if the structure was to fail, it would fail due to buckling first. This EInπ was found by comparing the critical Eulerian buckling load ( P = 2 L 2 ),(using a buckling factor of 0.25 based on the boundary conditions of the strut) to that of the load that would cause axial yielding. Then, the critical Eulerian buckling load was compared to that of the expected load. It was found that the expected load was well below that of the critical buckling load. In factor, even with a factor of safety of 3 applied to the expected

4 operating load, it was found that the minimum thickness of the vertical strut would need to be 13.1mm (~0.5 ). However, after some discussions with the machine shop and knowing that other components would be bolted to the vertical struts, the thickness was set to be 50.4mm (2 ). At 50.4mm thick, 1255mm in height, and 203.2mm in width, the struts had a buckling factor of safety (with respect to the expected operating load) of 19.3 which was assumed to be sufficient. In addition to this, from the assumed loading, the axial strain of the strut (height wise) was found to be on the micron scale and thus would likely not affect cut quality in any way. Note that all calculations used material properties for A36 steel. Next, the material needed to be defined. As previously mentioned, the struts would function as datums and previous calculations used material properties of A36 steel. So rather than choosing a new material, A36 steel needed to be justified. It was found that not only was A36 steel commonly ground to precise tolerances, but it was also one of the most common structural steels used for industrial applications in the United States. It was a low carbon steel that had good strength, able to be galvanized for corrosion resistance, easily weldable, and also relatively easy to machine. After some preliminary searches from various vendors to check for sizings and availability, it was found that the material was also readily available. Thus, it was believed that A36 could in fact be a good material for the vertical struts. Moreover, a machining (grinding) operation should be called out to ensure high flatness tolerances on the faces of the struts in which items would be mounted. In order to better understand how the struts would mount to the guide roll system, the following CAD model was created:

5 Here, the three black vertical pieces are the struts that mount up against the guide roll system. The rest of the workpiece movement system essentially sits on top of these struts. Summary of Research

6 A36 Steel Easily Machinable Low carbon steel Good strength Good formability Easy fabrication Readily available in common sizes from various vendors Can be galvanized Increase corrosion resistance Extremely common in buildings, warehouses, etc. (industrial structural steel) Elastic Modulus: 200 GPa Yield Strength: 250 MPa Poisson s Ratio: 0.26 Density: 7800 (kg/m^3) Summary of Design Height 1255mm Subject to change if any of the critical dimensions change Width 203.2mm Dependent on largest workpiece Dependent on gaps between gussets Thickness 50.4mm Oversized with respect to buckling/yielding failure modes Extra size to allow for added rigidity as well as material to bolt into Material A36 Steel Should be held to relatively high tolerance Other Holes will need to be added to mount bearing rails Holes will need to be added to mount to guide roll team s angle plates Possibility of other holes to be added unknown at this time Relatively cheap (~$400 for raw material) Moving Forward

7 In order to ensure the integrity of the design, various actions should be taken to ensure the completion of the vertical strut design. First, flatness and squareness tolerances should be added to the drawing. The struts ultimately supply datums for the whole system to move up and down and thus the flatness of the mating surfaces should be held to a tight tolerance. Next, a vibration analysis (first principle or finite element) should be completed to see how the struts will react to driving frequencies from the motors in the system. Although a DVA could be added, one should try to ensure (by design) that the frequencies of operation are not near the natural frequencies of the struts (as well as all of the other components). Since the width and thickness of the struts were chosen to be common sizes (8 and 2, respectively) they should be relatively easy to purchase and then it would just be cutting them to length. This would require searching through various vendors to find the material and should be completed after finalized drawings (including all tolerances, any size adjustments, etc.) and a vibration analysis are completed.

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