Freeing Rings/Motor Measurements

Continuing with the machining of the rings, we decided to take a hacksaw to the steel sheet:

This method was met with success as we had no trouble freeing the outside of the ring structure. 

We were also able to complete the wiring for our motor today. Upon successfully setting the device so that the motor speed would vary via a potentiometer, we decided that motor placement would be tackled next:

Seeing that the length of each of the components would be too long to create a single tiered motor box, we propose a two shelf system.We aim to produce a motor box that will have the electrical components at the top while the motor is at the bottom. In addition, we also look to design the box so that the motor can be easily be slid in and out of the oven opening. 

Day 2 Rings and Motor Set Up

Today we finished the machining of the rings. Shout out to Christie Taylor's group for allowing us to use their machining slot. The rings finished with little trouble until the very end, in which our tool broke. With no replacement tools ready at hand, we called it a day and removed the sheet of steel:

With the rings still not freed, Bob Stark suggested that we use a hacksaw at the appropriate places to finish the process. 

Ring Machining

Machining of the rings today out of of a half inch thick sheet of steel. We first cut out a piece of acrylic for the jig on the CNC machine:

During the machining, the support structures were tapped by Andrea and Dan:

In order to begin the machining of the rings, it was suggested that we drill and tap 4 holes into each of the three rings and attach them to the acrylic jig below.this ensures that he rings will not move during machining.

Machining would continue until roughly 7 PM, at which point, the first ring was finished and the inside of the second ring was in progress:

Post-Spring Break

Consulted today with Robert Stark on motor selection. It appears that will we use the following motor along with an Arduino microcontroleer in order to vary the speed settings:

Tomorrow we aim to machine the three rings for our device.

Machining of Stands

Having sent the Creo drawing of the outside stands/housing to Senior Lab Technician Mohamed Haroun, we were ready to machine. Essentially, the files were used in accordance with Mastercam in order to produce the desired G-Code. 

Consulting with Lab Manager Robert Stark, we were able to flatten the surface of two of our 6 bearings in order to easily mount them to the outside stands. This was done on the lathe. 

Adjusting the CNC machine accordingly in order to mount our first piece of stainless steel, our team was ready to begin machining after gathering the required mills/bits:

Initially there were concerns regarding the stability of the support structures. However, as the cutting process was nearing the end, one lab member used a glove to hold onto the freed side of the steel before pulling the piece away from the drill to ensure it did not come loose. The cutting process went smoothly and lasted roughly 2 hours for each side of the housing:

For the first housing piece, the order of the cutting went as follows: inside removal, drilling of holes, then outside material removal. For the second housing, we drilled the holes first, then went for the removal of the inside and outside in order to minimize the changing of the tools. Our final product:

In the meantime, Andrea also went to pickup our oven in New Jersey:

Design Review II

After presenting at the Design Review II, which was peer reviewed by the Ark group, we decided that the best option moving forward with our project is to purchase an entirely new oven. Given this option, we will be able to mount our new design choice of a DC motor to the side of an oven. We will have to run the drive shaft through the oven side however.

A review of the design will be done in order to ensure ease of machining as we will be importing into Mastercam in order to make use of a CNC machine. Such difficulties include that of the inner ring, where a redesign will be done for the attachment of the rods holding the dough.

Contained below is the ideal set-up of our design moving forward:
Ideal_Use

Also, below is the link to our Design Review II written report:
Design Review II Report

Finally, below is out CAD Layout and specific dimensions/numbers are available upon request:

Post-Winter Break Meeting

A meeting following the winter break was held to ensure we were properly prepared for the Design Review II presentation. Tasked were divided up as follows:

Andrea: Full, fleshed out order sheet in preparation for any parts to be ordered on Stock Drive, including part numbers.

Dan: State and design variable definitions as specified by the grading rubric. Also, to start looking into other forms of website designs such as social media via Facebook and/or Twitter

Tom/Brendan: Finishing touches to the overall CAD while looking into a new model for the smaller ring but multiple muffin design. Aim to dimension the parts as well in order to have a complete presentation during Design Review II. This will also give our group a realistic approach to the machining stage and what can or can not be done by tools available to us.

Brian: Look into starting the paper version of the Design Review II as well as updating schedules. Consult with professors with regards to the use of aluminum subjected to the heat of an oven.

A new concern has risen with regards to the motor selection. It appears that the originally selected spring loaded motor has plastic parts, which clearly will be detrimental during use in an oven. Research into alternative methods such as ceramic 3-D printing will also be done, especially with Shapeways, Inc.