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BallMillingVessel-FinalReport-Fall2009

BallMillingVessel-FinalReport-Fall2009 - EML 4905 Senior...

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EML 4905 Senior Design Project A SENIOR DESIGN PROJECT PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING Ball Milling Vessel Design for Hydrogen Infusion into Powders with Sensory Feedback Ahmed Al-Bahar Roger Garcia Jimmy Sandoval Advisor: Professor Dr. Chen November 20th, 2009 This report 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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2 Ethics Statement and Signatures The work submitted in this project is solely prepared by a team consisting of Ahmed Al- Bahar, Rog er Garcia, and Jimmy Sandoval 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. Ahmed Al-Bahar Team Leader Roger Garcia Team Co-Leader Jimmy Sandoval Team Co-Leader Dr. Chen Faculty Advisor
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3 TABLE OF CONTENTS Chapter Page Cover Page 1 Ethics Statement and Signatures 2 Table of Contents 3 List of Figures 4 List of Tables 4 Abstract 8 1. Introduction 9 1.1 Problem Statement 9 1.2 Motivation 11 1.3 Literature Survey 12 1.4 Discussion 20 2. Project Formulation 21 2.1 Overview 21 2.2 Project Objectives 22 2.3 Design Specifications 23 2.4 Constraints and Other Considerations 24 2.5 Discussion 25 3. Design Alternatives 26 3.1 Overview of Conceptual Designs Developed 26 3.2 Design Alternate 1 26 3.3 Design Alternate 2 27 3.4 Feasibility Assessment 28 3.5 Proposed Design 29 3.6 Discussion 31 4. Project Management 33 4.1 Overview 33 4.2 Breakdown of Work into Specific Tasks 34 4.3 Organization of Work and Timeline (Timeline for Senior Design Organization and Senior Design time frame) 35 4.4 Breakdown of Responsibilities Among Team Members (Indicate Each Member‟s Major and Support Roles for Each Task) 36 4.5 Patent/Copyright Application 37 4.6 Commercialization of the Final Product 38 4.7 Discussion 41
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4 5. Engineering Design and Analysis 42 5.1 Kinematic Analysis and Animation 42 5.2 Dynamic/Vibration Analysis of the System 45 5.3 Structural Design 47 5.4 Force Analysis 49 5.5 Stress Analysis 50 5.6 Material Selection 54 5.7 Design Based on Static and Fatigue Failure Design Theories 55 5.8 Deflection Analysis 56 5.9 Component Design/Selection 61 5.10 Finite Element Analysis 66 5.11 Design Overview 66 5.12 Cost Analysis 68 5.13 Discussion 69 6. Prototype Construction 70 6.1 Description of Prototype 70 6.2 Prototype Design 71 6.3 Parts List 72 6.4 Construction 76 6.5 Prototype Cost Analysis 76 6.6 Discussion 76 7. Testing and Evaluation 77 7.1 Overview 77 7.2 Design of Experiments - Description of Experiments 78 7.3 Test Results and Data 84 7.4 Evaluation of Experimental Results 88 7.5 Improvement of the Design 92 8. Design Considerations 94 8.1 Assembly and Disassembly 94 8.2 Maintenance of the System 96 8.2.1 Regular Maintenance 96 8.2.2 Major Maintenance 97 8.3 Environmental Impact 98 8.4
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