DETAIL DESIGN REVIEW
OCTOBER 26TH 2012
Team P13656: L. Abatte, W. Fritzinger, P. Torab, K. Karauda
Project Management: Plan

Project Schedule
Design Proposal

Ultrasonic, self-contained unit
Design Proposal

http://prezi.com/kjnwnkg7awaz/ultrasoniccleaningsystem/?auth_key=30636a7d6cb66176bbd1c45f
00a37499b77e2f32
Specifications
Specifications
Coating & Extrusion Die Compositions


SS 400
carbon
0.05
silicon
1
Manganese
1
chromium
12
phosphorus
0.03
aluminum
0.25
sulfur
0.03
iron
85.64
Honeycomb Extrusion Dies
 TiCN
(coating)
Reaction Equations Set Up





Define the underlying reactions
Obtain redox potentials and equilibrium constants
for perspective reactions
Developing the reaction rates & heat generated by
the exothermic reaction
Utilize non-linear reaction program analysis to
generate reaction scheme
Define optimization based on reaction scheme
Reaction Sets

Redox Reactions
 Decomposition
of H2O2
 Acidic Stabilization
 Ti Redox reactions
Variable Stripping Parameters
From US Patent 20070023943
Validation Test Samples
Bar Stock Dimensions
 cross-section: square 2in x 2in
 thickness: 0.5 in



Capillaries: 9 units, 1/16 in
Coating: TiCN
Body: 316 SS
Sample Picture
Variable Test Samples
Panel Dimensions
 Length = 2 in
 Width = 2 in
 Thickness = 0.025 in


Coating: TiCN
Body: 304 SS
Variable Test Sample

Sample Denotation
 FREQUENCY:
2 samples
 TEMPERATURE: 4 samples
 COMPOSITION: 4 samples
 FINAL/SPARES: 5 samples
Total: 15 Samples
Polarization Cell Components







Test Sample
Two Auxiliary Electrodes
Luggin Capillary
Salt Bridge Connection
Inert Gas Connections
Thermometer
Glass Container
Functionality of Polarization Cell





Adjusting potential of auxiliary electrode 1 to
match the potential of the sample.
Measuring the current flowing across the other
auxiliary electrode 2 and sample.
Reference current flowing between the two
auxiliary electrodes.
Generation of a Taffel plot
Taffel plot deduced corrosion rate [mass/time]
Prototype Testing




At this time there would be defined test conditions
along with a prototype system.
The test will act as a check to the validation testing
and variable testing.
Coated mini-dies will be used in the testing.
Reaction check
Supply & Cost Analysis for Testing
Pugh Chart
A
B
C
D
E
F
G
H
I
J
K
L
Sub
Functions
Score
Criteria
Cost
Return on investment
Ease of use
Availability
Maintenance
Corrosion resistance
Fatigue
Lifetime
Aesthetics
Performance
Safety
Ergonomics
Sum +
Sum 0
Sum -
Concepts
Updated Vert
+
0
+
0
+
+
0
0
0
0
+
5
6
1
Rotary
0
0
0
+
+
+
+
0
0
0
4
6
2
Ultrasonic
+
+
0
+
0
+
+
+
0
+
7
3
2
Concepts
Updated Vert
Radial
Ultrasonic
Horizontal
Move parts in a
horizontal
motion
1
Create flow over entire
surface
Move parts in a
vertical motion
Move parts
radially
Ultrasonic
vibration
2
Create flow through
capillaries
Move parts in a
vertical motion
Move parts
radially
Ultrasonic
vibration
3
Minimize chemical bath
degradation
4
Maintain bath temperature
5
6
7
8
Move parts in a
horizontal
motion
Cover tank; limit
contaminates
around tank
Use current
system
Use current
system
Keep solution
agitated
Keep solution
agitated
Cover tank;
decrease cycle
time
Heating system
included in many
designs
Keep solution
agitated
Cover tank;
redirect vapors
Cover tank;
redirect vapors
Cover tank;
redirect vapors
Cover tank;
redirect vapors
Increase corrosion
resistance of materials
Select corrosion
resistant
materials
Select corrosion
resistant
materials
Select corrosion
resistant
materials
Select corrosion
resistant
materials
Operating instructions
Prepare
handbook
containing
graphics;
maintenance
table;
documentation
Prepare
handbook
containing
graphics;
maintenance
table;
documentation
Prepare
handbook
containing
graphics;
maintenance
table;
documentation
Prepare
handbook
containing
graphics;
maintenance
table;
documentation
Controls in safe
spot; joints and
pinch points
reduced;
shielding
Cover tank;
redirect vapors
Controls in safe
spot; joints and
pinch points
reduced;
shielding
Cover tank;
redirect vapors
Controls in safe
spot; joints and
pinch points
reduced;
shielding
Cover tank;
redirect vapors
Controls in safe
spot; joints and
pinch points
reduced;
shielding
Cover tank;
redirect vapors
Maintain homogeneous
mixture
Reduce corrosive
environment exposure of
system
9
Protect Operator
10
Limit exposure to
chemicals
Cover tank; limit Cover tank; limit
contaminates
contaminates
around tank
around tank
Horizontal
+
0
+
0
+
+
+
+
+
0
0
+
8
4
0
Use current
system
Keep solution
agitated
Project Management: Risks

Risk Matrix
Bill of Materials - Rotational
Description
Supplier P/N
Tank
Unit Price
Quantity Total Cost
Supplier
Owner
Lead Time
Status
$0
1
$0.00
CTI
CTI
N/A
Existing
NEMA 56 1/2hp wash-down motor
59845K68
$355.59
1
$355.59
McMaster - Carr
Will
In Stock
Planned
High-efficiency speed reducer
6481K77
$247.15
1
$247.15
McMaster - Carr
Will
In Stock
Planned
Corrosion resistant chain (1 ft.)
5960K1
$60.34
3
$181.02
McMaster - Carr
Will
In Stock
Planned
Shielded thrust bearing
60715K15
$20.26
1
$20.26
McMaster - Carr
Will
In Stock
Planned
Stainless steel shaft (1")
6526K55
$114.57
1
$114.57
McMaster - Carr
Will
In Stock
Planned
Shaft collar (1")
9665T2
$68.65
1
$68.65
McMaster - Carr
Will
In Stock
Planned
Drive sprocket (10 teeth)
6799K112
$50.25
1
$50.25
McMaster - Carr
Will
In Stock
Planned
Driven sprocket (24 teeth)
6799K127
$99.80
1
$99.80
McMaster - Carr
Will
In Stock
Planned
316 SS rectangular bar stock (6ft.)
9083K11
$74.12
1
$74.12
McMaster - Carr
Will
In Stock
Planned
Polycarbonate sheet (12"x36"x1/8")
8574K265
$32.48
1
$32.48
McMaster - Carr
Will
In Stock
Planned
Rotational System
Rotational System
Rotational System
Bill of Materials - Ultrasound
Description
Supplier P/N
Unit Price
Quantity
Cost
Supplier
Owner
Lead Time
Status
6 Gallon Cleaning Unit
SC-6
$3,462.00
1
$3,462.00
Severe Clean
Peter
TBD
Planned
Design Validation
Preliminary Testing:
 Necessary Equipment:
 Small
size ultrasonic tank
 Square test pieces:
2
x 2 in 316 steel (0.50 in thick)
 Coating: TiC, TiN, TiCN (since the exact coating of the actual
parts cannot be disclosed)

Optionally: HSS drill bits can be used as test pieces (coated with
TiN)
 H2O2
bath (composition equal to the one used by the
customer)
Design Validation

Procedure:






Test pieces will be weighed and the initial weight will be recorded (prior
to and after coating)
Test pieces will be submerged in the tank
Throughout the duration of the test, steel will be removed from the tank
several times and weighed. This will provide the data necessary for
establishing the rate at which the coating is being stripped from the
parts by the bath.
Test will also provide the data for establishing the bath degradation
rate since the ultrasonic tank will be at different pressure and
temperature compared to the current setup.
Testing will be conducted for several test pieces to provide reliable data
and avoid measurement error.
Once the data is obtained it will be analyzed and presented to the
customer as well as faculty guides.
Design Validation

Variables:

Frequency:
What value is optimal?
 Range of acceptable values


Temperature:

Natural convection: temperature gradient throughout the tank (visit
to vendor -> investigation)
Solution composition
 Vibration intensity/ transducer strength
 Cavitation strength
 Jamestown Advanced demo

Design Validation

Vendors:
 McMaster
Carr for sheet metal/ steel pieces
 Vergason for coating of the test pieces
 All machining can be done in house utilizing the ME
machine shop
Optional

In the future the design
can be further
expanded:
 Level
switch
 Secondary containment
tank
 Piping system for fluid
recycling purposes
Questions?