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TWELFTH WEEK
ASSIGNMENT
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COMPOSITE                 

  Assignment    

  • Design and make a 3D mold (~ft2), and produce a fiber composite part in it.
motors

This assignment has two parts, the first is to make a mold for solving practical issues, the second part is to make something about my final proyect.

For this assignment I planned to do something we could use in the work shop, mi colleague Hermenegildo Mendoza, who is responsible for the mechanical maintenance shop, needs covers for the capacitors of some electrical motors.

FIRST PART:    COVER

There are single phase electrical motors which work with capacitors and they generally are on the external cover,  This cover is secured with screws.

 cover2


mezclando


MAKING A MOLD


First I used an existing cover to make a mold.

I made a  cardboard container where I placed the cover, then I poured the "DryStone" mix filling the whole container.


caja_tapa

WORKING THE MOLD
Drying the mold
molde2

The mold outside the container
molde3

You can see the original cover.
molde4
The mold before the final finish
molde5

Giving the final touches
lijando
COMPOSITE

First, car wax is used to allow easy removal.
molde_con_cera
COMPONENTS

I have fiberglass and POX BAK, It is composed of a resin and a catalyst, and in order to be used it has to be prepared, the parts being added in a 2:1 ratio.

       epoxy          pox_bak2         fibra
secando

 preparando

aa

CONCLUSIONS:
  • You have to improve the finish, very thin and fragile at the edges.
  • I think it's best to prepare a male / female mold.
  • The glass fiber had to be bigger, to cover the edges.
  • A layer of resin was first pass and then place the fiber.
  • It is necessary to experiment more.


SECOND PART:  ABOUT MY FINAL PROYECT

I have the need to implement a stator for my final project.

THE MOLD

The stator contains a three-phase winding composed of 9 star-connected coils.
 
These have to be placed in the center of a mold where the synthetic resin is poured. When it dries, it must have the necessary rigidity to be part of the wind turbine and will rotate at a maximum speed of 1800rpm.

Among the different parts of the mold I have placed a plastic sheet to make it easy to unmold.

                    The files are attached  here



 





COILS
Coil reel has been designed with 123 Design and formed proportionally with two covers together in the center; that is because it leaves a better finish on the inner faces of the reel. If full print, I will need support and this leaves a very irregular surface.



PREPARATIONS:
  • Fiberglass is cut according to the diameter of the mold which is then prepared for the manufacture of its both sides.
  • The mixture is prepared in a ratio of 100/20.
  • The coils are placed and centered.
  • Cable reel must go through the hole prepared for it.

 COMPOSITE.
I will show you the sequence:

A thin layer of resin is first applied, then a layer of fiberglass is placed, then the coils are placed. More resin is poured carefully to reach all the cavities. After that, the second fiberglass layer is placed ...

...and finally the mold is completely filled. Apply light blows so that we fill all cavities.
 Then we proceed to completely close it. It is very important to keep it in a horizontal position.

24 hours after opening the mold process, with much expectation.


CONCLUSIONS:
  • It is important to read the data sheets for the material to be used.
  • I had to put more fiberglass edges.
  • It is then necessary to ensure that the resin penetrates all cabidades mold.
  • It is necessary to experiment more.
estator
This video shows the location of the stator in my final project.
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