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2011spr-T11-TrimRemovalSystem-FinalReport

2011spr-T11-TrimRemovalSystem-FinalReport - EML 4905 Senior...

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EML 4905 Senior Design Project A B.S. THESIS PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING Trim Removal System Final Report Paul Hoffman Omar A. Espino Walter McKinley Advisors: Dr. Sabri Tosunoglu Dr. Andres Tremante April 20, 2011 This B.S. thesis is written in partial fulfillment of the requirements in EML 4905. The contents represent the opinion of the authors and not the Department of Mechanical and Materials Engineering.
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P a g e | 2 Ethics Statement and Signatures The work submitted in this project is solely prepared by a team consisting of Paul Hoffman, Omar A. Espino, and Walter McKinley and it is original. Excerpts from others’ work have been clearly identified, their work acknowledged within the text and listed in the list of references. All of the engineering drawings, computer programs, formulations, design work, prototype development and testing reported in this document are also original and prepared by the same team of students. Paul Hoffman Team Leader Omar A. Espino Team Member Walter McKinley Team Member Dr. Sabri Tosunoglu Faculty Advisor Dr. Andres Tremante Faculty Advisor
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P a g e | 3 Table of Contents Table of Contents ............................................................................................................................ 3 Table of Figures .............................................................................................................................. 6 Table of Tables ............................................................................................................................... 9 Table of Equations ........................................................................................................................ 11 Abstract ......................................................................................................................................... 12 1. Introduction ............................................................................................................................... 13 1.1 Introduction to Project ........................................................................................................ 13 1.2 Problem Statement .............................................................................................................. 13 1.2.1 Cost Analysis Outline .................................................................................................. 14 1.2.2 Cost Analysis Summary ............................................................................................... 14 1.3 Literature Review ................................................................................................................ 16 1.3.1 The Spool Trim winder ................................................................................................ 16 1.3.2 The Vacuum Trim Removal ........................................................................................ 18 2. Engineering Design ................................................................................................................... 20 2.1 Modeling ............................................................................................................................. 20 2.1.1 Vacuum Force at Venturi ............................................................................................. 21 2.1.2 Drag Force in Waste Disposal Duct ............................................................................. 24 2.2 Waste Disposal Pipe ........................................................................................................... 25 2.2.1 Pressure Drop ............................................................................................................... 25 2.3 Blower Selection ................................................................................................................. 28 2.3.1 Blower Specifications .................................................................................................. 29 2.3.2 Blower Decision ........................................................................................................... 29 2.3.3 Integrating Disposal Pipe with Blower ........................................................................ 31 2.4 Venturi Design .................................................................................................................... 33
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P a g e | 4 2.4.1 The Venturi Operating Principle .................................................................................. 33 2.4.2 Design Objective .......................................................................................................... 34 2.4.1 Conceptual Designs ..................................................................................................... 35 2.5 Fluid Dynamic Analysis of a Venturi ............................................................................. 37 2.5.1 CFD Simulations .......................................................................................................... 42 2.5.2 CFD Modeling Studies ................................................................................................ 45 2.5.2 – Iterative CFD for Correlation to Blower Operating Point ........................................ 52 2.5.3 Iterative CFD for Nozzle ............................................................................................. 56 2.6 Final Design .................................................................................................................... 67 2.7 Conclusion and Recommendations ................................................................................. 70 3. Construction and Testing .......................................................................................................... 73 3.1 Construction ........................................................................................................................ 73 3.2 Testing ................................................................................................................................. 77 3.2.1 Testing Overview ............................................................................................................. 77 3.2.1.1 Test Procedure .......................................................................................................... 77 3.2.1.2 Test Equipment ............................................................................................................. 78 3.2.3 Test Results ...................................................................................................................... 80 3.3 Overall Cost/Benefit Analysis ............................................................................................ 81 4. Project Management ................................................................................................................. 83 4.1 Work Breakdown Structure ................................................................................................ 83 4.2 Breakdown of Project Time ................................................................................................ 84 4.2.1 – Estimated of time required ........................................................................................ 84 4.2.2 Record of Actual Time Required ................................................................................. 85 4.3 Resource Management ........................................................................................................ 87 4.3.1 Roles and Responsibilities ........................................................................................... 87
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P a g e | 5 4.3.2 Human Cost ................................................................................................................. 88 4.3.3. Financial Cost ............................................................................................................. 88 5. Conclusion ............................................................................................................................ 90 6. References ............................................................................................................................. 91 6.1 Engineering Analysis and Design ....................................................................................... 91 6.2 3D Modeling and Simulation Resources ............................................................................ 91 6.3 Plastic Manufacturing Vendors ........................................................................................... 91 6.4 Pump Vendors ..................................................................................................................... 92 6.5 Noise ................................................................................................................................... 92 6.6 Project Management ........................................................................................................... 92 7. Appendix ............................................................................................................................... 93 7.1 Hand Calculations ............................................................................................................... 93 7.2 Pressure Loss in Waste Disposal Pipe Calculations ........................................................... 97 7.3 CFD Iterations ................................................................................................................ 98 7.3 Test Data ...................................................................................................................... 111 7.3 Engineering Data .............................................................................................................. 113 7.4 Engineering Drawings .......................................................................................................... 114 7.5 Receipts ............................................................................................................................. 118
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P a g e | 6 Table of Figures Figure 1 – Materials starts as a large spool and ends as a plastic bag. ......................................... 13
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