Week 10 Mechanical Design, Machine Design

Group assignment

We decided to make a vacuum foaming machine.

My part is to make 3D design and purchase and make parts.

Group site

Result

We completed as below;

Foamed PP
Painted

Machine

Idea phase

• Our lab don't have a vacuum foaming machine. It sounds a good trial to make it as assignment of week 10.
• We have an old 3D printer out of order, the sensor and step motor might be utilized.
• We use cleaner as Vacuum function.

• Heating is function is not decided yet.
  

• Stage size is A4, 5mm thick aluminum

• Frame 20 x 20 aluminum
• Stage is supported by 4 linear shaft and bushing.
• Auto stop with limit switches at top and bottom.
• Actuation with 2 step motors.
• Automated heating is challenging, so we try this next version. This time we heat it manually with heat gun etc. Then start automated vacuum foaming.
  

My part

• Designing the structure and making 3D model.
• Order/3D print structure parts and assemble.

Process

3D modeling

1. Frame

   • I bought frame parts from Misumi, and its web site shares 3D model of their product. I just downloaded and opened with SolidWorks.
     
   • Downloaded 3D model
   • 3D model of assembled frame is also available

2. Vertical shaft and bushing

   • I bought shaft and bushing unit for vertical actuation from Amazon.
     
   • Amazon does not offer 3D model for its products. I measured actual size once I received the parts, then created 3D model.
     
     
     
   • Assembled on Solidworks
     

3. Motor

   • We utilize existing motor, I measured actual size and 3D modeled.
     
   • I also created 3D model of motor holder.

4. Stage and film holder

   • Our plan was to make it with 5mm thick Aluminum as designed below.
   • Stage
     
   • Film holder

5. Pulley holder

   • We utilize pulley from an old 3D printer. I measured the pulley box and created 3D model to attach it to the frame.
     
   • For left and right parts, I prepared mirror copy.
     

6. Stage holder

   • This part is to connect linear bushings and the stage.
   • I carefully designed of clearance from other parts, motor and pulley at top and bottom end.
     
     
   • This part needs to be connected actuating belt.
7. Vacuum box and coupler
   • Vacuum box as the base of the machine. We planned to connect a vacuum machine to this box.
     
8. Complete 3D model
   • Assembled 3D model and confirmed each size are fine (No friction, no interferance)
     
     

Making of the parts

1. Frame

   • Easily built up, but must confirm each parts connected right angle.
     

2. 3D printing parts (Pulley holder, Stage holder, Vacuum box coupler)
   
   

   • Then put insert nuts into the parts with a soldering iron.
     

3. Stage and film holder

   • Aluminum plate before cutting
   • Cutting 5mm thick aluminum plate with our lab's original CNC.

- Need to lubricate cutting oil so that the cutting friction heat not going high. Otherwise the tip of aluminum melt and you cannot cut.

- Once cutting completed, remove the tabs.

- Made screw holes with a screw tap

4. Vacuum box
- I cut a plywood with our CNC.
- Then build up a box

Assembling

1. Put linear shaft and bushings on top and bottom frames.
   
2. Put pulley holders with pulleys on lower frames.
3. Put stage holders on linear bushings. 　　
4. Put motor holders and motors on top frames. Then belt up with the pulleys.
5. Put the stage on stage holders
   
6. Put limit switches on top and bottom frames.
   • bottom frame
     
   • Top frame