Pin Router Duplicator

Introduction:

This testing report is for a pin router duplicator, designed for Central Washington University class MET 345 (Lean Manufacturing) The requirements of the project requires the spring to be used as a counterbalance to bring the four bar linkage system back to a neutral position. Professor Beardsley provided the spring. The parameters of interest in this requirement include an application of force being applied to the four bar linkage system. Predicted performance, as calculated in the complete project report, the spring rate is 15.5lbs/in. Data will be collected by using a 2ft ruler (with 1/64 increments) and spring scale to measure the applied force and deflection. Testing for this experiment will occur during the weekend of April 8th, 2017

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For Test 1:

For the first test, the spring that's provided by Professor Beardsley is tested for deflection to determine the spring rate. As mentioned above, the predicted performance for the spring rate is 15.5lbs/in for a predicted weight of 25lbs. However, after testing, the spring rate came out to be 14lbs/in, which failed to be used as a counterbalance, so a second test is to be performed.

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For Test 2:

For the second test, a new spring was ordered because the previous spring did not work as a counterbalance. The calculations for the predicted performance was off, due to a wrong approximation of the weight of the router head. The parameters of interest in this requirement is that the new spring has a spring rate that is higher than the predicted value. After a few tests, the deflection of the system are collected. Now, the new spring rate is 18.34lbs/in. The goal is to be able to use the new spring as a counterbalance. Testing for this experiment will occur during the weekend of April 23rd, 2017.

 

Method/Approach:

Resources for both tests will be provided by Central Washington University at no cost. The data, as mentioned above, will be collected by a 2ft ruler. Equipment includes a spring scale (to apply force), safety glasses, 2ft ruler (with 1/64 increments), and other miscellaneous tools as needed. The spring scale will be used to apply force to the system to determine the deflection, from when the system is in its neutral position. To ensure that the system does not fail, a maximum of 30lbf will not be exceeded. Data will be collected by hand using a 2ft ruler (with 1/64 increments), and then recorded into a spreadsheet using Microsoft Excel, where it can be stored, manipulated, and analyzed.

 

Testing Procedure 1:

For this test, the spring that’s provided by Professor Beardsley will be analyzed. Testing is scheduled to take place during the weekend of April 8th, 2017. It will take approximately two to two hours, which will be performed in the senior project room, located in Hogue at Central Washington University. However, if no unexpected issues or failures, the actual experiment could take less time.

1. Position the 4 bar linkage system in a neutral position (both plates are parallel with each other)

2. Position the 4 bar linkage system to get ready to plunge into the part (the position where the router bit is touching the MDF table)

3. Take initial measurements of the plate (that holds the router and stylus), measured from the bottom of the plate to the MDF table.

4. Measure the distance with a 2ft ruler with 1/64 increments. This ensures the accuracy to four decimal places.

5. Put a welding wire on top of the stylus mount (the mount to the left of the router), where the hole is.

6. Attach the spring scale onto the welding wire and apply force by pulling down.

7. Do this for 10lbf, 20lbf, and 30lbf.

8. Take measurements of the deflection of the system with a 2ft ruler with 1/64 increments.

9. Repeat steps 5-8 five times.

10. Record data and insert into an Excel spreadsheet

11. Graph Deflection vs. Applied Force

In order to ensure safety of the operators, personal protective equipment (safety glasses, gloves, and etc.) will be used. Potential failures could result in the spring snapping into pieces if not handled with care. However, according to calculations, the spring shouldn’t snap.

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Testing Procedure 2:

For this test, the spring that is ordered from McMaster Carr, will be analyzed. Testing is scheduled to take place during the weekend of April 22nd, 2017. It will take approximately two to two hours, which will be performed in the senior project room, located in Hogue at Central Washington University. However, if no unexpected issues or failures, the actual experiment could take less time.

1. Position the 4 bar linkage system in a neutral position (both plates are parallel with each other)

2. Position the 4 bar linkage system to get ready to plunge into the part (the position where the router bit is touching the MDF table)

3. Take initial measurements of the plate (that holds the router and stylus), measured from the bottom of the plate to the MDF table.

4. Measure the distance with a 2ft ruler with 1/64 increments. This ensures the accuracy to four decimal places.

5. Put a welding wire on top of the stylus mount (the mount to the left of the router), where the hole is.

6. Attach the spring scale onto the welding wire and apply force by pulling down.

7. Do this for 10lbf, 20lbf, and 30lbf.

8. Take measurements of the deflection of the system with a 2ft ruler with 1/64 increments.

9. Repeat steps 5-8 five times.

10. Record data and insert into an Excel spreadsheet

11. Graph Deflection vs. Applied Force

 

In order to ensure safety of the operators, personal protective equipment (safety glasses, gloves, and etc.) will be used. Potential failures could result in the spring snapping into pieces if not handled with care. However, according to calculations, the spring shouldn’t snap.