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

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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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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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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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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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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Table of Figures
Figure 1 – Materials starts as a large spool and ends as a plastic bag. ......................................... 13