Marketable3DPrinter-FinalReport-Fall2009

Marketable3DPrinter-FinalReport-Fall2009 - EML 4905 Senior...

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1 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 Marketable 3-Dimensional Printer William Mendez Keith Richardson Karan Sujan Advisor: Dr. Kuang-Hsi WU November 20 th , 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 William Mendez, Keith Richardson, and Karan Sujan 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. William Mendez Team Leader Keith Richardson Team Member Karan Sujan Team Member Dr. Kuang-Hsi WU Faculty Advisor
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3 Table of Contents List of Figures ................................................................................................................................. 7 List of Tables ................................................................................................................................ 13 1. Introduction ............................................................................................................................... 14 1.1 Problem Statement .............................................................................................................. 14 1.2 Motivation ........................................................................................................................... 15 1.3 Literature Survey ................................................................................................................ 15 2 Project Formulation ................................................................................................................... 28 2.1 Overview ............................................................................................................................. 28 2.2 Project Objectives ............................................................................................................... 28 2.3 Design Specifications ......................................................................................................... 29 2.4 Constraints and Other Consideration .................................................................................. 29 3. Design Alternatives ................................................................................................................... 30 3.1 Overview of Conceptual Designs Developed ..................................................................... 30 3.2 Design Alternate 1 .............................................................................................................. 41 3.3 Design Alternate 2 .............................................................................................................. 42 3.4 Design Alternate 3 .............................................................................................................. 43 3.5 Feasibility Assessment ........................................................................................................ 44 3.6 Proposed Solution ............................................................................................................... 45 3.7 Discussion ........................................................................................................................... 45 4. Project Management ................................................................................................................. 46 4.1 Organization of Work and Timeline ................................................................................... 46 4.2 Breakdown of Responsibilities among Team Members ..................................................... 47 5. Engineering Design and Analysis ............................................................................................. 48 5.1 Dynamic Analysis of the System ........................................................................................ 48 5.1.1Description of the System: ............................................................................................ 48 5.1.2 State Variable System Representation ......................................................................... 50 5.1.3 Belt Drive Parameters .................................................................................................. 51 5.1.4 System Graph ............................................................................................................... 52 5.1.5 Elemental equations ..................................................................................................... 52 5.1.6 Node or Vertex equations ............................................................................................ 54
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4 5.1.7 Compatibility or Path equation .................................................................................... 54 5.1.8 State Variable Equations .............................................................................................. 55 5.1.9 Initial Variable Conditions ........................................................................................... 61 5.2 Software and Hardware Integration .................................................................................... 68 5.2.1 Rapid Prototyping ........................................................................................................ 68 5.2.2 Implementation of CAD .............................................................................................. 69 5.2.3 The STL CAD File ....................................................................................................... 73 5.2.4 The Numerical Control Implementation for RP Systems ............................................ 77 5.3 Material and Parts Selection ............................................................................................... 81 5.3.1 Printing Material Selection .......................................................................................... 81 5.3.2 Motor Selection ............................................................................................................ 83 5.3.3 Motor Pulleys and Belts ............................................................................................... 87 5.3.4 Bearing Selection ......................................................................................................... 89 5.3.5 Fan Selection ................................................................................................................ 95 5.3.6 Insulation and Heating Element Selection ................................................................... 96 5.4 Position Analysis ................................................................................................................ 97 5.5 Stress Analysis .................................................................................................................... 98 5.5.1 Printer Frame 1 ............................................................................................................ 98 5.5.2 Printer Frame 2 .......................................................................................................... 103 5.5.3 Printer Frame 3 .......................................................................................................... 106 6. Prototype Construction ........................................................................................................... 109 6.1 Description of Prototype ................................................................................................... 109 6.2 Parts List and Cost Analysis ............................................................................................. 109 6.2.1 Plexiglass Features ..................................................................................................... 109 6.2.2 Bearings ..................................................................................................................... 112 6.2.3 Belts and Pulleys ........................................................................................................ 112 6.2.4 Electronics .................................................................................................................. 112 6.2.5 Extruder Parts ............................................................................................................. 113 6.2.6 Hardware .................................................................................................................... 113 6.2.7 Rods and Wires .......................................................................................................... 114 6.3 Construction ...................................................................................................................... 115 6.3.1 Bottom Construction .................................................................................................. 116
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5 6.3.2 Construction of Sides ................................................................................................. 117 6.3.3 Additional Side Construction ..................................................................................... 118 6.3.4 Top-Frame Construction ............................................................................................ 120 6.3.5 Diagonal Construction ............................................................................................... 121 6.3.6 Installation of Y motor ............................................................................................... 123 6.3.7 Installation of X motor ............................................................................................... 125 6.3.8
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